In an increasingly data-driven industrial landscape, the ability to monitor, analyze, and act on energy usage in real time is critical to achieving operational efficiency and sustainability. Itanta collaborated with a global leader in bearing manufacturing to elevate their digital footprint and optimize operational energy management.
A significant focus of the project was gaining visibility into the plant’s highest energy consumers-including compressors, chillers, furnaces, transformers, lighting systems, and air handling units (AHUs) – to enable more informed and timely energy decisions.
This case study explores how this global leader in precision engineering, leveraged the Itanta Analytics platform to modernize its Energy Management System (EMS)
at its Bangalore facility.
Highlights:
- Unified platform for monitoring 80+ energy meters in real time
- Custom dashboards for shift-wise and equipment-level visibility
- Live data updates every few minutes-no coding required
- Helps align plant operations with sustainability and smart factory goals.
- Scalable success—They expanded Itanta to other plant sites after proven results at the initial facility
This is not just a case of digital transformation-it’s a blueprint for how industrial facilities can harness no-code analytics to turn raw data into real-time intelligence.
Background
Driving Innovation in Bearing Manufacturing and Smart Industrial Operations
This case focuses on a prominent bearing manufacturer operating in India, backed by a globally recognized European engineering group. With a legacy dating back to the early 20th century, the organization has become a key player in India’s industrial ecosystem, operating multiple manufacturing facilities and maintaining an extensive distribution and service network.
The company serves a wide range of sectors, including automotive, energy, construction, aerospace, and general manufacturing. Known for its commitment to innovation, the enterprise champions a Lean, Green, Digital (LD) strategy-leveraging smart manufacturing, loT integration, and sustainability practices. Flagship programs exemplify its push toward operational excellence through digital transformation, reinforcing its position as a forward-looking leader in the industrial space.
System Architecture
1. Data Acquisition
The acquisition layer uses Itanta DS Manager to bring data into the system. Two key components enable this:
- SQL Connector: Connects to external databases and brings in relevant data efficiently.
- Unified Namespace Configuration: Organizes incoming data in a clear and consistent way, making it easier to manage, access, and use across the system.
2. Data Aggregation
In this layer, data is processed and transformed using the built-in Formula Builder.
- Formula Builder: Allows users to create custom calculations and apply logic to the data-without writing any code. This helps turn raw data into meaningful metrics that match specific operational or business needs.
3. Data Visualization
This layer enables users to easily interpret data through customizable dashboards.
- No-Code Dashboard Builder: Empowers users to build real-time dashboards using drag-and-drop components like pie charts, tables, and line graphs. These visual tools help monitor key metrics such as power consumption.
4. Data Distribution
The distribution layer supports various channels to share insights and reports, ensuring flexibility in delivery.
- Scheduler: Automates the sending of reports and alerts through multiple options such as email, data exports, and notifications. In this case, email was primarily used to keep stakeholders consistently informed and enable timely decision-making.
Itanta's Approach
No-Code Intelligence, Real-Time Action
The Itanta platform was deployed as a full-stack, real-time analytics layer over the client’s existing SCADA and PLC infrastructure. It brought together data, automation, and visualization-without requiring custom code or IT complexity.
Key capabilities delivered:
- Native SQL Connector to pull live data from SCADA/PLC systems seamlessly
- Unified dashboards like Monitor View and Graphical View gave stakeholders a complete view of energy flow-across all sources and consumption points
- Formula Builder automated daily, shift-wise, and monthly consumption calculations-minimizing manual reporting
- Live data refreshes ensured timely detection of anomalies or sudden spikes in usage
- Shift Configuration enabled clear performance comparisons across shifts, helping identify patterns and inefficiencies
- Role-based access delivered personalized views for operators, engineers, and managers-so each team saw only the data they needed
The result was faster insights, better alignment across teams, and smarter, data-led decisions at every level.
Sneak peek of the Dashboards
1. In the Monitor View, the following tables and pie charts are used to show the consumption.
2. Main Consumption Overview dashboard displays real-time energy consumption data across various sources like EB, DG, and Solar, along with power factor and transformer metrics.
Results
The implementation of Itanta’s analytics platform upgraded manual reporting to real-time, shift-wise insights for faster, smarter decisions
Energy tags integrated from Iconic Scada
Automated report generation
The implementation achieved a clear return on investment (ROI) within just 6 months.
Operational perspective across energy sources and consumption points gained by the stakeholders.
Shift-level analysis allowed teams to track and compare performance across 3 daily shifts. All meter data was unified into one platform, reducing information silos.
Conclusion
The successful deployment of Itanta Analytics showcases how modern manufacturers can unlock real-time energy intelligence through a no-code, scalable, and highly integrable platform, which provided this manufacturer with a unified, intuitive view of its entire energy ecosystem.
What did this Bearing Manufacturer achieve with Itanta:
- Unified energy view across the entire plant-live, accurate, and accessible
- No-code platform— enabled fast setup with zero coding or IT burden
- Native connectors—seamless data flow from 80+ meters and sources
- Live dashboards— instant insights for engineers, planners, and leadership
- Faster decisions— eliminated delays caused by manual reporting
- Reduced costs—no need for custom development or technical resources
- Supports sustainability goals—through real-time energy tracking and optimization
In a world where data is the new utility, Itanta Analytics enables manufacturers to not just collect data-but to act on it, in the moment it matters. Itanta isn’t just a platform-it’s a catalyst for smart, data-driven manufacturing.
