Imperial Auto Industries Ltd. is a leading auto parts manufacturer and supplier in India, specializing in high-pressure hydraulic tubes, tubular components, and fluid transmission products for OEMs across automotive and industrial sectors. With multiple manufacturing facilities operating 24/7, the company relies heavily on energy-intensive processes such as tube forming, heat treatment, CNC machining, and surface finishing.
As energy costs surged and sustainability targets tightened, Imperial Auto sought a smart energy management solution to reduce operational expenses, enhance efficiency, and gain real-time visibility into plant energy consumption.
The Challenge
Before implementing Jugno EMS, Imperial Auto faced several operational challenges:
- Lack of real-time visibility into electricity, compressed air, and utility consumption
- High peak demand charges from DISCOMs
- Unidentified energy leakages and idle load losses
- Manual data logging and delayed reporting
- Difficulty in tracking energy cost per unit of production
- Compliance pressure for ESG and sustainability reporting
Energy accounted for a significant portion of manufacturing overheads, directly impacting EBITDA margins.
The Solution: Jugno EMS
Imperial Auto implemented Jugno EMS (Energy Management System) across its production units to digitally monitor and optimize energy performance.
Key Features Deployed:
- IoT-enabled smart energy meters across critical equipment
- Real-time dashboard for plant-wide energy visibility
- Peak demand monitoring & alert system
- Energy analytics with AI-based anomaly detection
- Production vs energy correlation tracking
- Automated reporting for management & ESG compliance
Jugno EMS seamlessly integrated with existing PLCs and SCADA systems, ensuring zero disruption to production.
Implementation Approach
- Energy Audit & Baseline Creation
Jugno conducted a comprehensive energy audit to identify high-consumption zones. - Metering & IoT Deployment
Smart meters were installed on compressors, furnaces, CNC lines, and utility panels. - Data Analytics & Benchmarking
Energy KPIs were established for each production line. - Optimization Strategy
- Load balancing to reduce peak demand penalties
- Compressor scheduling optimization
- Idle load elimination
- Preventive maintenance alerts
Within weeks, plant managers gained complete control over energy consumption patterns.
Results Achieved
1. Significant Cost Savings
- 12–18% reduction in electricity bills
- Peak demand charges reduced by optimizing load during non-critical hours
- Identification and elimination of energy leakages
2. Improved Operational Efficiency
- Real-time monitoring improved decision-making speed
- 8–10% improvement in machine utilization efficiency
- Reduced downtime through predictive alerts
3. Energy Cost Per Unit Optimization
Jugno EMS enabled Imperial Auto to track energy consumption per component manufactured, helping:
- Improve pricing strategies
- Optimize batch production
- Enhance cost control
4. Sustainability & ESG Impact
- Reduced carbon footprint
- Automated sustainability reporting
- Improved compliance with energy efficiency norms
Business Impact
By leveraging Jugno EMS, Imperial Auto transformed energy management from a passive accounting function into a strategic operational advantage.
Key Business Benefits:
- Higher EBITDA margins
- Data-driven plant management
- Reduced operational waste
- Faster ROI (achieved within 8–12 months)
- Scalable deployment across multiple plants
Energy optimization became a competitive differentiator, strengthening Imperial Auto’s position in the Indian automotive components industry.
Why Jugno EMS Was the Right Fit
- Industry-specific energy intelligence for manufacturing
- Scalable IoT architecture
- AI-driven analytics
- Seamless integration with existing systems
- Measurable ROI
Conclusion
In today’s competitive automotive manufacturing landscape, managing energy efficiently is no longer optional — it is essential.
Imperial Auto Industries’ adoption of Jugno EMS Energy Management System demonstrates how smart manufacturing technologies can significantly reduce energy costs, improve plant operations, and enhance sustainability performance.
Through real-time energy monitoring, peak demand control, and actionable analytics, Imperial Auto successfully achieved cost savings, operational excellence, and long-term energy efficiency — setting a benchmark for auto parts manufacturers in India.