Smarter expansion saves millions through power measurement at Roxtec International

Roxtec International discovered through power measurement that their actual power needs were significantly lower than estimated, saving millions during expansion.

Roxtec International

Roxtec International manufactures cable and pipe seals that protect installations against fire, gas, water, vibrations, and electromagnetic interference.

The Challenge

When maintenance manager Pontus Jönsson began measuring energy usage with SenseNode in 2022, the primary purpose was to understand and report energy consumption. However, the measurements provided critical insights for the company's upcoming expansion.

Maintenance Manager Pontus Jönsson shows the planned expansion.

Surprising effect patterns

Measurements quickly revealed an unexpected pattern—the highest power consumption occurred in summer rather than winter, contrary to initial assumptions. This was due to the company's integrated heating system, where heat from the extruder was reused as district heating during winter but had to be cooled away in summer.

Expansion backed by data

With growing demand, Roxtec planned a major expansion. Traditionally, power needs are calculated by summing each machine’s peak power and then applying a standardized reduction, as all machines rarely operate simultaneously. When these theoretical calculations were compared to actual measurements from SenseNode, the difference was striking—actual peak loads were often just one-third of the estimated requirement.

“By sizing based on real data instead of theoretical calculations, we were able to avoid costs in the millions”

Pontus Jönsson, Maintenance Manager

Concrete savings

Improved solar energy usage:

Power measurement confirmed that solar energy production peaks matched the facility’s energy demand, maximizing self-consumption and profitability.

Reduced power subscriptions:

Better understanding of power requirements allows for the cancellation of two out of four power subscriptions.

Avoided unnecessary investment in high-voltage transformer:

Measurement data showed that the actual power needs were significantly lower than calculated, avoiding a planned investment in a new high-voltage transformer, saving millions of SEK.

Underestimated social benefits

Oversized power calculations are a widespread issue causing unnecessary expansion of the power grid. Inflated estimates often lead to installing excessive power capacity that remains unused. With limited power availability in the grid, and suppliers needing to balance demands, there is also a risk of investments or expansions not occurring, despite being feasible.

“If more industries had accurate power metering, it would provide major benefits for the entire electricity grid”

Pontus Jönsson, Maintenance Manager

Solution

Data Collection

Energy Analytics

Advisory

ISO 50 001

Energy Mapping, EKL

CSRD directive

Integrated Energy Reporting

Case Studies

Management

Production

Sustainability