Interview with the Methods and Energy Manager at Metalis

Interview with Enzo Allamassey, Methods and Energy Manager at a Metalis site.

User of the Enkel solution since February 2025

April 2025

What was your need?

"We needed to monitor the site's electricity consumption data.

So, at the end of January 2025, I turned to Enkel sensors, which allow us to delve into the details of machine consumption. Secondly, we wanted to assess the most energy-intensive items on the site."

Firstly, what were you able to do with our equipment?

"The Enkel system allowed me to discover a lot of things, particularly regarding the compressors. These compressors were running on weekends to power two machines. We noticed that the actual consumption of the compressors compared to the compressed air requirements for the wire EDM machines was oversized, so we will install another compressor for these machines by May/June. This will allow us to achieve energy savings that we'll be able to measure at that time.

The EDM machine is what allows us to process the material to make blocks, dies, or elements that we use for cutting, since we specialize in cutting. These elements are manufactured in parallel on weekends, so it saves us a lot of time.

We run 3x8 shifts without weekends, but some machines run in parallel on weekends because these operations are extremely time-consuming, and we need these parts on Monday morning to be able to use them."

So you installed sensors on these machines specifically?

"On the compressors to determine their current consumption on weekends. We realized that it wasn't wise to leave our compressors running at that time, so we're going to invest in a small compressor that will take over on weekends so we can consume less and better than our needs. The Enkel solution allowed us to calculate the energy cost of a production unit produced on weekends by these compressors and realize that it was too high and that it would be better to invest in new equipment to reduce costs. Some were oversized for the required production level and required motor overhauls, which would cost the company more than a new investment."

How many sensors have you installed in the factory?

"So in the factory today, we have an E-case (a portable case) and 16 sensors. As a methods manager and energy specialist, I was able to see thanks to the sensors that there are still improvements to be made."

What kind of improvements?

"For example, we had two different maintenance companies for two compressors, so we consolidated this service into a single company, which allowed us to save money."

What else have you noticed thanks to our solution? 

"I have a sensor on our perchloroethylene water degreaser. It's a very old machine, 20 years old, so the idea is to be able to compare the electricity consumption of this machine with that of the new one that will arrive in May. The goal is to validate the energy savings in terms of decarbonization."

Are you aiming for ISO 50000 certification?

"For the moment, it's not planned in the short term, but when it is, 99% of the work will be done thanks to the installation of sensors."

And then, have the sensors helped you on other types of machines to check for problems or to implement measures?

"Yes, for example, the Enkel sensors helped us detect very long inspection times on certain machines: motors, conveyors, presses, which are very energy-intensive. We therefore decided to modify their use by turning off all peripherals after a certain period of inactivity of the cutting press. The goal is to reduce our consumption, simply by educating operators to restart and shut down the machines so that they only consume power when we need it.

Furthermore, I also analyzed the consumption of the general outputs of our production units (PU), which allowed me to notice a fairly significant consumption gap in certain PUs, particularly the first. Thanks to the sensors, I will be able to retrieve detailed data in the PU to determine what this consumption corresponds to and find the source of the problem."

On the Save it Yourself platform, what feature do you use the most?

"I mainly use the load curve, less the diagrams and histograms."

Have you already been able to quantify the energy and financial savings achieved by measuring before and after the upgrade?

"This is a work in progress.

Typically, for the power supply of an EDM machine, investing in a small compressor to replace an old one, which would allow the main compressor to be shut down, represents a savings of approximately €10,000 on this process (valid from May to December).

On this production unit alone, we have a very good return on investment of around 7 to 8 months.

In addition, we will have the same savings each year.

For the main compressor part, which we will also be replacing, the annual savings in terms of consumption and maintenance will be €10,000 to €11,000 for a return on investment of 2 to 3 years. All this without taking into account the savings that the standard exchange would have cost, with a virtually zero return on investment.

In addition, for the machines in the production units, automation systems will be installed to automate shutdown, standby, and start-up settings. The savings are estimated at €2,000, with a return on investment of less than a year.

So, all the steps are more or less underway regarding the electrical component, with a total of at least €22,000 in savings per year. The remaining savings will be the gas component.

Have you discussed this experience with our sensors internally with the other Metalis Group sites?

"Yes, we have a review with the other Energy representatives, so we communicate on these topics within the group. Even though each site operates at its own pace, the approach is disseminated and supported."