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IoT and Smart Controls: Transforming Energy for Large Manufacturers

Technology has recently evolved to help large manufacturers better manage their energy usage, resulting in potential cost savings as we look ahead, its crucial for businesses to plan strategically for a sustainable future. The integration of Internet of Things (IoT) and Smart Controls has played a pivotal role in this transformation, allowing for precise control over lighting resources while minimising waste and environmental impact. In this blog, we’ll explore how IoT and Smart Controls benefit large manufacturers by optimising energy consumption and reducing expenses. Renewable Energy Solutions aims to take on the role of using these advancements and tailoring them to a specific business’s needs.

What are IoT and Smart Controls?

The use of IoT and Smart Controls plays a significant role in modern energy and technology in collecting and sharing data. The digital intelligence of these device enables communication with each other without human interaction. It has emerged from the concept of machine-to-machine (M2M) communication. Within Smart Controls, energy management helps in reducing the use of electricity consumption in building facilities and large manufacturers. Implementing effective energy management not only minimises waste and optimises resources but also fosters more sustainable and environmentally friendly practices. With IoT technology and Smart Controls, you can gain valuable insights and take timely actions, making your energy usage more secure, consistent and efficient.

Which Smart Controls Benefit Manufacturers?

  • Lighting Controls

    IoT-enabled lighting systems, such as LED Lighting, allows for the automated activation of lights based on occupancy sensors, daylight harvesting, and scheduling algorithms. By dynamically adjusting lighting levels according to occupancy patterns and natural light availability, businesses can significantly reduce energy waste without compromising on illumination quality or comfort.

  • HVAC Management

    Heating, ventilation, and air conditioning (HVAC) systems account for a substantial portion of energy consumption in commercial and industrial buildings. Smart controls enable the optimisation of HVAC operations by adjusting temperature settings, airflow rates, and ventilation schedules based on occupancy patterns, occupancy sensors, and weather forecasts. By fine-tuning HVAC systems to match actual demand, businesses can achieve substantial energy savings while maintaining optimal indoor comfort levels.

  • Most Appliances Can Be Placed In Energy Saving-Mode

    In addition to lighting and HVAC systems, IoT and smart controls offer the capability to manage the energy consumption of various appliances and equipment within buildings and manufacturing facilities. By implementing energy-saving modes, scheduling operations during off-peak offices, and remotely controlling appliances, businesses can minimise standby power consumption and reduce overall energy usage without sacrificing operational efficiency.

The integration of IoT devices and smart controls enables manufacturers to streamline their operations through automation and remote management capabilities. From regulating HVAC systems to controlling lighting and monitoring equipment performances, smart controls empower businesses to achieve greater operational efficiency by automating routine tasks and adjusting energy usage.


IoT-enabled devices and smart controls offer real-time monitoring and analysis of energy usage, empowering businesses to identify areas of wastage and implement proactive measures to optimise consumption. By fine-tuning energy usage patterns, manufacturers can not only maintain cost savings but also contribute to sustainability efforts by minimising their carbon footprint.

How Can Manufacturers Benefit From This?

Businesses often unknowingly consume energy when it’s not necessary, leading to a spike in energy bills. Manufacturers can benefit from cost reduction through optimising their energy usage and maintaining equipment to extend lifespan, saving on repair and replacement costs.


Additionally, automating processes lowers labour expenses.  Previously said, IoT and Smart Controls have real-time monitoring which allows manufacturers to identify and address quality issues promptly, ensuring that products meet standards and reducing the risk of defects or recalls. This level of monitoring allows for highly precise inventory management, ensuring that stock levels are optimised to meet demand without excess or shortage. Additionally, the IoT and Smart Controls usage timely intervention in case of any deviations from optimal storage conditions, such as temperature or humidity fluctuations, helping to maintain product quality and reduce waste.


Despite facing resistance, major manufacturers are actively pursuing ways to reduce their dependence on fossil fuels. With government support, they’re transitioning their energy-intensive operations toward cleaner, low-carbon technologies in manufacturing processes. The government emphasises that the Industrial Energy Transformation Fund (IETF) targets businesses with high energy consumption, aiding their shift away from fossil fuels. This initiative not only promotes environmental sustainability but also helps companies lower their energy costs.


Another consideration is the expiration of gas or electricity contracts, resulting in automatic transitions to pricier tariffs known as ‘out-of-contracts’ or ‘rollover rate’. At RES, we make sure our clients are always aware of when their contract is coming to an end, avoiding out-of-contract rates and have a clear plan in place for when contracts do end.

Helping Manufacturer’s on the Road to Net-Zero

With the growing emphasis on renewable energy sources, businesses are increasingly investing in solar panels, wind turbines, and other clean energy technologies. IoT and smart controls play a crucial role in facilitating the integration of renewable energy systems by providing visibility into energy generation, storage, and consumption. By orchestrating the seamless interaction between renewable energy sources and traditional grid infrastructure, businesses can maximise the utilisation of clean energy resources and further reduce their reliance on fossil fuels.


Nevertheless, Make UK’s manufacturing members have released the conclusive report detailing the roadmap to achieving net-zero emissions within the sector. This roadmap outlines how companies, and their respective sub-sectors will play pivotal roles in establishing four low carbon industrial clusters by 2030. These clusters aim to significantly reduce energy consumption and carbon emissions. Transitioning your manufacturing processes will be crucial in paving the way for sustainability, utilising resources such as IoT and Smart Controls to efficiently manage energy consumption.

While the decreasing energy bills in the UK may present a favourable scenario for businesses in the short term, the long-term viability and competitiveness of organisations hinge on their ability to adapt and innovate in response to evolving energy dynamics. By harnessing the power of IoT and smart controls, businesses can unlock a multitude of benefits ranging from cost savings and operational efficiency to sustainability and corporate social responsibility, positioning themselves as leaders in the transition towards a more sustainable future.


Join us as we unravel the transformative potential of IoT, Smart Controls, and Renewable Energy Solutions, empowering manufacturers to navigate towards a greener and more prosperous future.

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