The Enspi Energy Ladder

Case Study
One such company, PrecisionManufacturing Inc., recently expanded itsoperations with a new CNC machine.While the addition promised to increaseproduction capacity, it also broughtunexpected and daunting energy costs.The local utility informed them that theywould need a transformer upgrade tohandle the new load, moving them into ahigher rate class. Within months,Precision Manufacturing saw its energycosts nearly double. Frustrated andfeeling boxed in, the company turned toEnspi to regain control. Through Enspi’s Energy Ladder—a three-step, modular approach that starts withBill Analyzer, moves to EnFut for real-time monitoring, and culminates withPowerUp, a Virtual Power Plant (VPP)solution—Precision Manufacturingtransformed their energy profile,unlocking significant savings, optimizingtheir energy usage, and ultimatelygenerating new revenue.

The Challenge

As Precision Manufacturing dealt with soaring electricity costs, they struggled to understand their bill’s complex structure. They suspected they were overpaying but didn’t have the tools to pinpoint the inefficiencies. They had no idea where to begin.

The Solution

1. Overlooked Billing Errors: Bill Analyzer revealed that the newly installed transformer, which the utility required to support their CNC machine, had bumped them into a higher rate class. However, after analyzing their usage, it became clear that the transformer wasn’t needed, and the 250KW demand level was well beyond their actual consumption.

2. High Power Factor Penalties: Bill Analyzer also identified a high power factor penalty due to the inefficient operation of some machines. The company was paying additional fees every month for this inefficiency.

3. Untapped Incentives: Through its incentives and rebates module, Bill Analyzer connected PrecisionManufacturing with a local energy efficiency program, securing a $7,500 grant to improve their operational efficiency.
Enspi introduced them to Bill Analyzer, an AI-powered platform that connects directly to the utility through a secure API and pulls up to 24 months of historical data. In a matter of minutes, Bill Analyzer detected issues in their billing structure.

The Outcome

By renegotiating their power agreement and optimizing the rate class, Precision Manufacturing was able to reduce its monthly bill by 30%. This was achieved with a straightforward platform setup in under 30 minutes and required no upfront capital. Bill Analyzer had given Precision Manufacturing a roadmap to immediate savings, proving that understanding one’s energy bill is the first and most crucial step.

The Challenge

While the initial savings were significant, Precision Manufacturing knew that energy usage fluctuates with production schedules and seasonal demands.They wanted a way to maintain optimal energy consumption continuously without the constant need for manual checks.

The Solution

Enspi’s EnFut platform provided real-time monitoring and management of their energy usage, offering an in-depth view of consumption patterns and allowing for ongoing optimization.

1. Continuous Monitoring of Energy Use: EnFut’s 24/7 visibility into energy data enabled PrecisionManufacturing to spot inefficiencies in real-time, such as equipment running during peak hours when demand charges were highest.

2. Automated Alerts and Reports: EnFut generated alerts when consumption spiked unexpectedly, helping the team prevent costly energy overages. Weekly reports provided actionable insights into machine performance, operational efficiency, and cost-saving opportunities.

3. Annual Cost Reduction Potential: With EnFut’s data-driven insights, Precision Manufacturing optimized itsoperations, reducing unnecessary energy wastage and avoiding peak demand charges. Over the first year,they saw an additional 30% reduction in their energy costs through continuous optimization.

The Outcome

By implementing EnFut, Precision Manufacturing gained full control over their energy profile, ensuring that the savings achieved with Bill Analyzer were sustained and even enhanced over time. They had moved beyond simply understanding their bill to proactively managing it, securing stability in their energy expenses.

The Challenge

After successfully optimizing their energy consumption, Precision Manufacturing was curious if they could turn their energy savings into an additional revenue stream. They had heard about Virtual Power Plants(VPPs) but weren’t sure how it applied to them as a mid-sized manufacturer without extensive renewable assets.

The Solution

Enspi introduced PowerUp, a Virtual Power Plant solution designed to aggregate energy resources across multiple facilities and provide demand response capabilities. Through PowerUp, Precision Manufacturing could participate in demand response programs, selling their conserved energy back to the grid during peak demand periods.

1. Grid Participation and Revenue Generation: PowerUp enabled Precision Manufacturing to participate in demand response events, reducing their load during grid stress periods and receiving compensation for doing so.

2. Optimizing On-Site Assets: As Precision Manufacturing considered adding solar and storage assets,PowerUp provided a pathway to maximize the value of these investments, allowing them to export surplus energy back to the grid.

3. Environmental and Economic Benefits: By contributing to grid stability and reducing emissions through optimized energy practices, Precision Manufacturing aligned with their corporate sustainability goals while generating up to $15,000 annually in additional revenue.

The Outcome

With PowerUp, Precision Manufacturing unlocked a new revenue stream and strengthened its role as aforward-thinking, sustainable manufacturer. They had climbed the full Enspi Energy Ladder—from understanding and reducing costs to generating income from optimized energy management. Their journey is a testament to the power of Enspi’s modular approach to energy efficiency.