Reducing Plant Electricity Costs

Cut plant electricity costs through data-driven insights: time-based consumption monitoring, load coordination, and solar integration. Hino Systech – Japanese standard engineering.

Challenges facing your business

  • Shift in Electricity Tariffs Leaves Plants Unprepared

    Current time-of-use electricity tariffs define peak hours from 17:30 to 22:30 (Monday through Saturday) and off-peak hours from 00:00 to 06:00 daily under Decision 963/QD-BCT.

    Concurrently, the two-component electricity pricing mechanism under Decision 14/2025/QD-TTg calculates charges based on both capacity demand and active energy consumption.

  • Visible Overall Utility Bills, Hidden Waste Hotspots

    The entire facility relies on a single master meter, or uses regional sub-meters recorded manually per shift. Consequently, energy consumption cannot be disaggregated by production line, underloaded machinery remains unidentified, zones with poor power factor (cos φ) are unknown, and daily peak demand timing goes untracked.

    "Energy-saving" initiatives are reduced to surface-level slogans like turning off lights—while massive energy waste during heavy motor and equipment operation remains completely unmonitored.

  • Recurring Waste on Every Monthly Bill

    Heavy electrical loads running during peak-tariff hours, compressors, pumps, and fans operating under no-load conditions, and rooftop solar output unmonitored and uncoordinated with facility demand—each item represents direct financial loss, recurring month after month.

    Without actionable data, enterprises cannot quantify individual waste streams, making it impossible to formulate retrofit investment plans backed by clear ROI calculations.

Technology Driven by Hino Systech Systems

Our approach

  • 1

    Granular Measurement at Every Switchboard and Production Line

    Hino installs power meters at key energy consumption nodes, connecting them directly to IIoT energy data acquisition gateways. Active power, total energy consumption, and power factor (cos φ) for each area are continuously logged over time—giving plant operators complete visibility into their hourly consumption patterns for the first time, moving beyond a single end-of-month total.

  • 2

    Multi-Protocol Conversion Gateway

    Hino Gateway 378 collects data from multi-vendor equipment (such as Siemens, Schneider, and ABB) via Modbus TCP/IP, communicates over the IEC 60870-5-104 protocol, and aggregates rooftop solar power generation data onto the same platform. Grid-purchased electricity and self-generated solar power are displayed on a single unified chart—an essential prerequisite for dispatching loads in alignment with solar output.

  • 3

    EMS/PMS Analysis & Reporting

    The EMS/PMS system analyzes consumption based on time-of-use tariff rates, issues alerts when demand approaches registered capacity limits, and cross-references energy usage across different facility zones and operational periods. Management gains a data-backed baseline to decide which production shifts to move to off-peak hours, which equipment to retrofit first, and how to accurately measure ROI after each operational change.

Reducing Plant Electricity Costs

New Operating System

Hino Systech Data Collection & Control Architecture

Hino Systech system solution details

  • A Single Partner Accountable for the Entire Lifecycle

    Hino Systech Vietnam is a 100% Japanese-owned company, drawing on over 70 years of expertise from the Hino Systech Group in Japan (established in 1950) and more than a decade of active operations in Vietnam. Over 20 Japan-trained engineers directly execute every phase—from load auditing, system engineering, and control panel manufacturing to installation and commissioning. Plant operators work with a single point of contact, eliminating hand-offs between separate hardware and software vendors where neither takes accountability during technical failures.

  • From Field Measurement Points to Management Dashboards

    The architecture features a seamlessly layered design: field-level measurement instruments and IIoT devices, Hino Gateway 378 at the communication layer, and SCADA with EMS/PMS at the monitoring and analytics layer. Data flows continuously with precise timestamps and zero inter-layer gaps, ensuring every conclusion regarding energy waste or retrofit performance is fully verifiable against raw baseline metrics.

    Hino’s large-scale energy data integration capability has been proven in real-world deployments, including projects for Luxshare-ICT (~20,048 kWp), Vikohasan Ha Nam (3,200 kWp), and a solar-generator-grid hybrid system at Sapporo Long An (~706 kWp).

  • Simultaneous Three-Pronged Reduction in Electricity Costs

    First, eliminate operational waste: pinpoint idle equipment, areas with poor power factor (cos φ), and abnormal load spikes for immediate corrective action.

    Second, optimize tariff management: flexibly shift loads to off-peak hours and control peak demand—a critical factor as two-component electricity pricing factors in capacity demand under Decision 14/2025/QD-TTg.

    Third, maximize rooftop solar yield: align facility load demand with solar generation to boost self-consumption rates. System-native performance tracking ensures every investment plan is backed by empirical ROI data rather than mere projections.

Get a Power-Quality Survey & Switchboard Design Quote

Optimize your plant's energy costs today with a smart power-factor correction system. Hino Systech's expert engineers will run an on-site measurement survey and propose the optimal technical plan — completely free.

0866868133 Contact via Website