Recovering 427k PLN annually on energy costs in a sand quarry
Data analysis showed that pumps worked at full power during peak price hours. We automated the machine work schedule.
Kruszywa Śląskie S.A. was losing huge sums because no one monitored when dewatering pumps consumed the most electricity. We implemented a system that controls the operation of 14 machines based on current energy tariffs. Results based on numbers showed that changing machine habits gives real cash after the first month.
The challenge
Energy bills at the plant near Gliwice jumped by 24.3% in just 11 months. The main culprit was a dewatering system based on 14 pumps with 75 kW power each, which worked chaotically. Morning shift workers started all devices simultaneously at 7:15 AM, exactly at the onset of the most expensive day tariff. This caused not only high consumption charges but also regular penalties for exceeding contracted power, averaging 8,400 PLN per month.
Our approach
Our team, consisting of a data analyst and an automation engineer, spent 19 business days on-site. We started by installing independent meters that measured electricity intake every 15 minutes. We analyzed logs from the last 3 years to understand how much water actually had to be pumped out for the pit to be safe. We discovered that the mine could safely suspend pumping for 4 hours during the day without the risk of flooding, which is key for avoiding price peaks.
The solution
We designed and installed controllers that automatically arrange the pump work schedule. The system checks the current time and tariff and then starts the machines in cascade to avoid overloading the network. We eliminated manual control, which was unreliable. Management received a simple dashboard in Power BI, where they see hard data from the production line. Zero redundant tables – only concrete amounts saved each day compared to the previous year.
Results
Thanks to automation, the mine stopped paying penalties for exceeding power, and most energy-intensive processes were moved to night and weekend hours. Industrial precision of reports allowed the CEO to make a decision on modernizing another plant based on the same data.
Timeline
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August 2023Energy audit and installation of 14 measurement points
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October 2023Building the control algorithm and testing on two pumps
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December 2023Full system implementation across the entire pit
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February 2024Analysis of the first full quarter and tariff optimization
"I was worried that changing the pump working hours would flood the pit, but the numbers don't lie. The water disappears just as fast, and 400 thousand stayed in the company. That was concrete."