📋 Case Study

Food & Beverage Batch Oven Peak Demand Management

Peak demand charges exceeding $180k/year due to simultaneous oven preheating cycles

🏗️ Project Overview

Frozen foods plant in Minnesota, USA

🎯 Challenge

Peak demand charges exceeding $180k/year due to simultaneous oven preheating cycles

🔧 Design Approach

Redesigned HMI scheduling interface with real-time kW forecasting (15-min horizon); deployed energy-aware batch sequencer with staggered start logic and dynamic priority arbitration based on delivery SLA and energy cost signal (via utility API)

📐 Design Diagram

AI-generated project design illustration

📐 Key Calculations

Demand Charge Avoidance

ΔkW × $/kW × 12 months

Result: $142,800

Primary ROI driver

HMI Update Latency Budget

t_latency < 100 ms per IEC 62443-3-3

Result: 68 ms

Ensures operator trust in real-time kW display

📊 Results

Peak demand reduced by 29%; $142.8k annual savings; no impact on batch throughput or OEE

💡 Lessons Learned

• •Energy-aware sequencing requires SLA-aware priority logic—not just time-based staggering
• •HMI latency must be measured end-to-end, not just network RTT

✅ Key Takeaways

• 1Energy-aware sequencing requires SLA-aware priority logic—not just time-based staggering
• 2HMI latency must be measured end-to-end, not just network RTT