Increasing Sustainable Efficiency Through Intelligent Energy Management in Paint Shops

Context & Problem

In the context of rising energy prices and increasingly strict environmental regulations, automotive manufacturers face growing pressure to improve sustainability without compromising production efficiency. Paint shops, known for their high energy and resource consumption, are particularly impacted.

Our partner needed to provide their customers with greater transparency into how energy and resources, such as electricity, gas, and water, are consumed across production processes. At the same time, they were looking for ways to identify inefficiencies and optimise usage, while ensuring compliance with evolving legal and sustainability requirements.

Another key challenge was the lack of centralised control over equipment operation. Without intelligent orchestration, systems could remain active when not needed, leading to unnecessary consumption and increased operational costs.

Facts & Figures

The solution enables significant efficiency gains, including a reduction in energy consumption of up to 30%, alongside a decrease in CO₂ emissions by as much as 30% and water usage by up to 40%. These improvements are driven by real-time transparency, advanced forecasting capabilities, and optimised control of equipment operations, all while maintaining overall equipment effectiveness (OEE).

Business Challenge & Why Accesa

Our partner aimed to develop an intelligent energy management solution that enables consumption-optimised production while maintaining operational performance. This required not only deep technical expertise but also strong domain knowledge in manufacturing processes and sustainability.

By collaborating with Accesa, our partner gained access to a fully managed, cross-functional team of experts, capable of supporting the entire software development lifecycle, from requirements engineering to deployment. Our flexible way of working ensured a fast time-to-market and alignment with their internal processes.

Equally important was our consultative approach, which helped shape the product vision and continuously refine requirements, even in a complex environment involving multiple stakeholders and evolving priorities.

Solution & Impact

Accesa contributed to the development of a comprehensive solution for monitoring, analysing, and optimising energy and resource consumption across paint shop operations. The platform provides real-time dashboards that offer full transparency at the plant, process, and equipment level.

Advanced analytics capabilities allow users to identify major energy consumers, track consumption trends over time, and perform detailed evaluations down to individual production units. Forecasting features support demand planning, while load peak analysis enables more efficient energy distribution.

The solution also introduces intelligent orchestration of equipment, ensuring that systems are switched on and off optimally, reducing waste without impacting production efficiency. As a result, manufacturers benefit from lower operational costs, improved sustainability, and stronger compliance with environmental standards.

Applicability & Current Status

The collaboration is ongoing, with Accesa continuing to support the evolution of the platform as part of a broader Manufacturing Operations Management ecosystem. Continuous improvements and feature development ensure that the solution remains aligned with industry demands and technological advancements.

This collaboration highlights how data-driven insights and intelligent automation can transform even the most resource-intensive manufacturing processes into more sustainable and efficient operations. By combining deep technical expertise with strong domain understanding, we helped our partner unlock measurable cost reductions, improve transparency, and support long-term sustainability goals.

If you're looking to achieve similar results in your manufacturing environment, get in touch with us. We’re ready to help you create and implement tailored solutions that turn your operational challenges into measurable business value.