How Etex optimised energy usage with real-time energy monitoring

From energy-intensive processes to clear insights

Etex is a global leader in lightweight construction materials, with plasterboard production being one of its most energy-intensive activities. High energy costs and strict environmental regulations made it clear that better visibility into energy consumption was essential.

Together with Sensr, Etex implemented an Energy Monitoring System (EMS) to track electricity, gas, water, and other energy sources across its production lines. By combining this data with process and quality information, Etex gained actionable insights to reduce waste without compromising product quality.

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Real-time monitoring that drives action

The EMS was first deployed at a pilot plant in Italy, where sensors were installed on key machines and production stages. This enabled real-time visualisation of energy consumption on the factory floor, allowing operators and engineers to detect inefficiencies and take immediate action. For example, by measuring water loss during the drying stage, they could determine whether boards were too wet or too dry, enabling adjustments that minimized energy waste.

Energy data was translated into clear reports for different roles:

• Real-time views for operators to intervene quickly. With data from every 10 minutes. 
• Process insights for engineers to optimise production parameters. With data such as production square meters and water loss during the drying process. 
• Daily reports for plant managers to identify trends and make strategic decisions to further optimize our operations.

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Scalable impact across plants

Following the successful pilot, Etex expanded the EMS to additional plants in Chile and Brazil, with plans to roll it out further across high-energy sites worldwide.

With Sensr as a long-term partner, Etex now has a scalable foundation to continuously optimise energy usage, reduce costs, and move closer to its sustainability ambitions.