Transforming Manual Power Monitoring into Real-Time Operational Intelligence

From Manual Meter Readings to Intelligent Energy Management

Many manufacturing facilities still rely on manual data collection for power monitoring. While effective in the past, manual processes consume valuable manpower, delay issue detection, and make it difficult to optimize energy usage.

That was the challenge faced by Pilmico Iligan, where operators manually collected readings from dozens of power meters across multiple production facilities.

TITUS addressed this challenge by implementing a centralized Energy and Power Management System (EPMS) powered by Ignition SCADA.

The solution integrates more than 47 power meters from multiple manufacturers—including Schneider Electric, Siemens, ABB, Acrel, and Circutor—into a single monitoring platform. The system provides operators with real-time visibility of electrical parameters, alarms, historical trends, and energy reports through an intuitive web-based interface.

Technology Behind the Solution

The solution combines several enterprise-grade technologies:

• Ignition Perspective for unlimited web-based visualization
• Tag Historian for industrial data collection
• PostgreSQL with TimescaleDB for scalable time-series data storage
• Metabase for automated reporting and dashboards
• RevPi industrial edge devices
• Secure OT network infrastructure

By utilizing TimescaleDB on top of PostgreSQL, the platform efficiently manages high-frequency historical data generated by industrial equipment. This enables faster trend analysis, long-term data retention, and improved performance for energy analytics.

Business Impact

The implementation delivers measurable improvements by:

• Eliminating routine manual meter readings
• Providing real-time operational visibility
• Detecting electrical abnormalities earlier
• Improving energy cost analysis
• Supporting future digital transformation initiatives

As manufacturing facilities continue embracing Industry 4.0, centralized power monitoring becomes a strategic investment—not simply an operational upgrade.