Tracking Carbon Emissions in Manufacturing
The client is the largest contact lens manufacturer in Taiwan and ranks fifth globally. Known for its high manufacturing and quality standards, the company carefully tracks and controls every step of the process, from product design through consumer use.
Maintaining cleanroom conditions is essential for production. Along with monitoring temperature and humidity, the company must ensure that the air remains free of contaminating particles.
To support sustainability efforts, the client sought a computerized solution to record and analyze production equipment capacity data and use those insights to create a new energy-efficiency policy.
This secure cloud-based monitoring solution enables seamless server room and data center infrastructure management through real-time data collection, remote access, and intelligent analytics.
ICP DAS USA’s Environment and Energy Management Solution:
The customer uses the ICP DAS USA’s PM-3133i-160P isolated three-phase smart power meter to collect power consumption data from plant facilities and equipment.
For environmental monitoring, the DL-100TM485P temperature and humidity data logger records temperature, humidity, and dust levels in cleanrooms. The DL-1020 temperature and humidity data logger module performs similar monitoring and recording functions on production lines.
The PMC-5231 power meter concentrator gathers power, temperature, humidity, and particulate matter (PM) data from both cleanrooms and production lines, then transmits the information to the control center via Ethernet using the Modbus TCP protocol.
In addition, the iKAN-124 industrial LED display provides real-time visibility of temperature, humidity, and PM data in cleanrooms and production areas. It also serves as an alarm display to notify personnel of emergencies or abnormal operating conditions.
Power Consumption Monitoring
The ICP DAS USA PM-3133i-160P isolated three-phase smart power meter provides highly accurate power measurements for plant facilities and equipment. Power consumption data is collected and transmitted to the PMC-5231 power meter concentrator via the Modbus RTU protocol for centralized monitoring and analysis.
Cleanroom Environmental Monitoring
The DL-100TM485P data logger monitors and records temperature, humidity, and particulate matter (PM) levels in cleanrooms. The collected data is sent to the PMC-5231 through Modbus RTU, enabling real-time environmental monitoring and management.
Production Line Environmental Monitoring
The DL-1000 Series is designed for industrial air quality monitoring in demanding environments. These IP43-rated modules can measure and record a wide range of environmental parameters, including PM1, PM2.5, PM10, CO, CO₂, HCHO, TVOC, NH₃, H₂S, temperature, humidity, and dew point. They also support timestamped data logging with storage for up to 180,000 records.
In this application, the customer uses the DL-1020 module to monitor temperature, humidity, and PM1, PM2.5, and PM10 levels on production lines.
Edge Computing and Centralized Data Management
The PMC-5231 power meter concentrator serves as the central hub for power and environmental monitoring. It collects and records power data from connected meters while supporting real-time monitoring, data logging, and device integration.
The PMC-5231 supports multiple communication protocols and includes a built-in web server, allowing users to view data and configure settings directly through a web browser. Its programmable IF-THEN-ELSE logic enables automated decision-making and rapid response to abnormal conditions.
When the system detects unusual voltage, current, gas concentrations, temperature, or other environmental conditions, the PMC-5231 can automatically send alerts via email, SMS, LINE, or WeChat. In this deployment, it consolidates power, temperature, humidity, and PM data from the facility and transmits it to the control center using the Modbus TCP protocol.
Real-Time On-Site Information Display
The iKAN Series industrial LED display provides a reliable and effective way to display operational and environmental data on-site. Designed for industrial environments, it offers high noise immunity, excellent reliability, and support for both ASCII and Unicode characters, enabling multilingual message display.
The iKAN Series supports multiple communication protocols, including Modbus TCP/RTU, CGI, and PROFINET, making it easy to integrate with equipment from various manufacturers.
In this application, the iKAN-124 display receives data and messages from the PMC-5231 via Modbus TCP. It provides operators with real-time visibility into temperature, humidity, PM levels, production status, and equipment conditions.
If equipment faults occur or environmental parameters exceed predefined thresholds, the PMC-5231 automatically triggers the iKAN-124 to display warning or emergency messages, helping personnel respond quickly and maintain safe, efficient operations.
Conclusion:
ICP DAS USA has been helping organizations improve energy efficiency and environmental management for many years. Its solutions have been successfully deployed across a wide range of industries. For example, a palm oil plant in Thailand uses an ICP DAS USA energy management solution to monitor and optimize machine power consumption, helping reduce energy costs while supporting preventive maintenance. In Taiwan, manufacturers have implemented ICP DAS USA environmental and leakage monitoring solutions to gain real-time visibility into factory conditions and enhance operational safety.
By combining energy management, environmental monitoring, and industrial automation technologies, ICP DAS USA helps businesses transform traditional facilities into smarter, more efficient operations. The company remains committed to supporting customers on their digital transformation journey and helping them achieve their sustainability and ESG goals.
