Client & context
High-pressure die casting plant supplying two-wheeler OEMs, three furnaces, shared compressor yard, single HT incomer.
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Demand managementReference benchmark
Die casting: eliminating the morning MD spike
Shift-start furnace pre-heat overlap and holding loads drove a predictable incomer spike every morning, quantified and sequenced for ₹4–8L monthly demand savings.
15–22%
MD reduction
−40 min
Shift-start overlap
₹4–8L
Monthly savings
The challenge
Every morning, all three furnaces ramped simultaneously while compressors started for holding pressure, creating a 20–30 minute MD spike unrelated to production output.
Our approach
Mapped furnace ramp curves against actual pour schedules from MES timestamps.
Staggered pre-heat windows with prescriptions pushed to shift supervisors on WhatsApp.
Automated alerts when holding load exceeded baseline for empty mould status.
Outcomes
15–22% reduction in billed maximum demand within one billing cycle.
40 minutes average reduction in concurrent high-load window at shift start.
₹4–8L monthly savings from demand charge and energy overlap reduction.
Anonymised reference benchmark from automotive die casting segment.
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