Industry Playbooks
Purpose-Built for Energy-Intensive Manufacturing
ZOE delivers measurable, verified energy savings — from steel foundries and textile mills to food processing lines and institutional campuses. Backed by 6 published case studies with 12–30% SEC reductions.
Industries We Serve
Ideal Facilities
Case Studies
6 Case Studies. Real Savings. Every Industry.
Click any industry to see waste sources, solutions, tools, and case studies.
Overview
12–30% reduction in Specific Energy Consumption — across 6 real facilities
SEC — the kWh your plant consumes per unit of output — is the only number that tells you whether efficiency is genuinely improving, or output is simply changing. Here's what ZOE measured and reduced at real facilities across India.
Specific Energy Consumption (SEC) Reduction
% reduction from baseline · IPMVP-verified M&V · hover a bar for actual SEC numbers
kWh / ton
17% SEC reductionkWh / kg
15.2% SEC reductionkWh / ton
30% SEC reductionkWh / pump
18% SEC reductionkWh / lakh SDP
12% SEC reductionWhere the waste hides
The same energy waste categories appear across every industry we've worked in. Most plants have several running simultaneously — undetected. Here's what ZOE found and fixed, with verified savings ranges from published case studies.
Compressed Air Systems
5 of 6 case studies
Leaks, over-pressure, and overlapping compressors waste energy continuously — including during shutdowns. Verified savings: ₹0.78L–₹12.11L/mo per facility.
Cooling, Refrigeration & HVAC
All 6 case studies
Chillers set colder than needed, fouled condensers, pumps running full-speed with throttled valves. Verified savings: ₹0.63L–₹7.35L/mo.
Furnaces & Process Heat
Steel & Automotive case studies
Open lids, excess hold time, heating above the required tapping temperature. The single largest savings category at heat-intensive facilities. Verified: ₹13.52L–₹13.62L/mo.
Idle & Auxiliary Loads
All 6 case studies
Fans, pumps, dust collectors, and lighting running through breaks, weekend shutdowns, and low-production windows — waste that rarely shows up in any single meter reading.
Power Quality & Demand Charges
All 6 case studies
Harmonics, phase imbalance, reactive power losses, and demand spikes inflate your electricity bill without adding output. Fixing them also prevents motor failures and tripping events.
Fan & Pump Speed Control
Textiles, Food & Campus
Running fans and pumps at full speed with throttled valves or dampers converts usable energy into heat. VFD retrofits verified at ₹1.35L–₹3.79L/mo per application.
What this means for your facility
Across 6 verified case studies, ZOE recovered 12–30% of the monthly electricity bill as real, measured savings.
These are IPMVP-verified figures from published M&V reports — not estimates or projections. Your actual results will depend on your current baseline, processes, and operating patterns.
₹6L – ₹15L / mo
verified savings range
₹12L – ₹30L / mo
verified savings range
₹24L – ₹60L / mo
verified savings range
Based on 12–30% of electricity bill recovered across 6 published case studies
Sector-Specific Wins
Real customer outcomes measured using IPMVP-based SEC methodology. Energy savings shown separately from total benefits.
FMCG Food Processing
30% SEC reduction
₹25.50L/mo energy savings
(₹29.00L/mo total benefit)
SEC dropped from 566.7 to 396.7 kWh/ton across 14 verified measures at a 2,000 ton/month facility.
Pump Mfg + Foundry
18% SEC reduction
₹34.74L/mo energy savings
(₹40.44L/mo total benefit incl. avoided failures)
SEC dropped from 105.2 to 86.3 kWh/pump across 16 measures plus ₹50L gearbox failure avoided.
Integrated Steel Plant
16.5% SEC reduction
₹161.70L/mo energy savings
(₹180.20L/mo total benefit)
24 verified measures at a ₹9.80 Cr/month facility. ₹120L gearbox + ₹45L electrical trip avoided.
Manufacturing leaders choose Zerowatt for measurable, proven ROI.
From steel foundries to food processing lines, ZOE adapts to your process, utilities, and team structure — delivering prescriptive guidance with IPMVP-based savings you can take to the CFO.