See where your plant’s electricity really goes
Per-feeder electrical monitoring for Indian industrial plants. Every machine measured, every finding explained with a cited standard, every rupee traced to a reading.
- Monitoring only, no control
- Every number traceable
- Works without internet
- Findings cite a standard
One meter at the incomer tells you the bill, not the cause
Most Indian plants meter electricity once. Nobody can say which machine is wasting energy, running overloaded or dragging the power factor down until it fails or the bill arrives.
Digital Shopfloor measures every motor feeder separately and turns the readings into specific findings, each with a standard, a recommended action and, where the arithmetic is defensible, a rupee cost per year.
- Which machine is overloaded, unbalanced or idling
- Why the power factor is penalised, and what to fix
- Sags and DG changeovers attributed to the supply, not blamed on machines
- Cost per hour, today, this month, in rupees
- Alerts that name the cause and the action
- Reports in plain English for any period
From feeder to finding in four steps
Measure every feeder
Multifunction energy meters on each motor feeder, read over RS-485 Modbus. Status modules can add contactor, overload and breaker state.
Collect locally
A gateway in your plant polls the meters, validates and stores every reading, and keeps working without internet.
Analyse with standards
Time-weighted analysis raises findings: what, where, how far from the limit, which standard, and what to do.
See it, act on it
Dashboards for owner, manager and operator; alerts that explain themselves; reports for any period.
Break a plant, watch it explain itself
A small simulated plant. Pick a scenario, click a machine, and see the finding the system would raise: the deviation, the standard, the cause and the action. All data here is simulated.
Rules the product never breaks
Monitoring only
No write path to any equipment: no start/stop, no overrides, no setpoints. It cannot affect your process.
No invented numbers
Every figure traces to a reading, a confirmed nameplate or tariff value, or a cited standard. Missing data shows as missing, never as zero.
Local first
Runs on a machine in your plant and keeps working with the internet down. Nothing leaves the site unless you configure it.
Supply problems are not asset problems
Sags and DG changeovers hit every feeder at once. They are attributed to the supply, not raised as a dozen machine alarms.
Alerts people keep reading
Each alert names the machine, the measured deviation, the likely cause and the action. Repeats merge; alerts close themselves when the condition clears.
Secure by default
No default accounts, TLS off the local machine, same-origin JSON-only writes and a strict content-security policy.
A findings catalogue tied to standards
| Finding | Detects | Basis |
|---|---|---|
PQ.V_UNBALANCE / PQ.I_UNBALANCE | Phase unbalance, motor derating and heating | NEMA MG-1 |
PQ.THD_V / PQ.THD_I | Harmonic distortion on voltage and current | IEEE 519-2022 |
PQ.UNDERVOLTAGE / OVERVOLTAGE / FREQUENCY | Supply quality outside nominal bands | Nominal bands |
SITE.SUPPLY_EVENT | Panel-wide events attributed to the supply, not to a machine | Cross-feeder comparison |
HL.OVERLOAD / HL.UNDERLOADED | Sustained overload; oversized, lightly loaded motors | NEMA MG-1, nameplate |
EN.POWER_FACTOR / LOAD_FACTOR / IDLE_RUNNING | Power-factor penalty, poor load factor, idle running | Your tariff |
REF.* | Deviation from design or commissioning reference bands | Nameplate / datasheet |
DQ.COVERAGE | Incomplete data; percentages use covered time only | Always shown |
One system, four ways of looking
Plant owner
Energy cost in rupees, today and this month; where the money goes; what is worth fixing first.
Plant manager / electrical in-charge
Live load and power factor by panel and machine; alerts with a cause and an action; reports for a chosen period.
Operator
Which machines are running, which need attention, and acknowledging alerts.
Commissioning engineer
Mapping each machine to its feeder and meter, placing it on the plant drawing, checking that data is arriving.
What you see in the dashboard
- Overview: live load, cost per hour, today's cost, critical alerts, energy tiles
- Plant and single-line views with live machine markers
- Alerts, Findings and plain-English Reports for any period and panel
- Trends, usage by period, multi-machine comparison and an hour-by-day heatmap
- Energy and payback: daily energy by panel and a payback calculator
- Device mapping for commissioning, with an ingest log
Honest status: prototype built, first real-meter site next
A working prototype exists and has been tested on simulated data against a real plant’s requirements. We are commissioning on real meters next, and we are inviting a small number of pilot plants. We only make savings claims from measured, verified data, after a baseline period.
Register pilot interestQuestions we’re often asked
Can it switch or control my machines?
No. Digital Shopfloor is monitoring only. There is no write path to any equipment, by design.
Does it need the internet?
No. It runs on a machine inside your plant and keeps working if the internet is down. Remote access is optional and only if you want it.
What do you install?
Multifunction energy meters on each feeder you want to see, an optional status module for contactor, overload and breaker state, and a gateway box in your plant. We install it non-invasively and map every machine with you.
Is the demo on this page real data?
No. The demo is simulated and labelled as such. It shows how the system reasons and what a finding looks like. Real findings come from your own meters.
What does it cost?
The model is a per-plant subscription plus hardware. We quote per site after a short survey and do not publish prices on this page. Savings claims are only made from measured, verified data.
Where does it stand today?
A working prototype has been built and tested on simulated data against a real plant's requirements. Commissioning on real meters is the next milestone, and we are inviting pilot plants to take part.
Tell us what you need — we’ll size it right.
Share your requirement and our engineers will respond within 24 hours with a clear, itemised offer.