Executive Summary

This isn't only about billing. Product quality is as much a part of this exercise as cost control — the same furnace instrumentation that isolates energy cost also gives, for the first time, a real record of the melt itself: temperature profile and cycle time against every heat, which is what lets rejection and quality KPIs be audited against how a heat was actually run, not just its outcome.

Today, Unimech bills and manages energy only at the single utility incomer — furnace melting cost, auxiliary utility cost, and demand risk are all invisible until they land as one combined number on the monthly TNPDCL bill. That bill already shows the cost of that blindness: demand charges alone are 67% of the assessment, and reactive-power and deviation penalties trace directly back to furnace operating behaviour nobody currently sees in real time.

Phase 1 meters the source (the utility incomer) and the plant's major consumer (the furnace), giving the running data needed to actually analyze the plant — kVA demand, kVAh, TOD slots, load-by-time visibility, temperature profiling — rather than reading it off a bill weeks later. It does not yet add automated control — that's Phase 3, and it depends on Phase 1 actually being in place first.