How a tea manufacturing plant used SEDAC Modbus-to-MQTT gateway and V-VAC IoT platform to gain real-time energy visibility, improve power factor, reduce wastage, and enable data-driven energy management.
The Challenge
The Challenge: Energy Data Locked in Meters The tea manufacturing unit had already installed digital energy meters on key machines and control panels. These meters collected valuable electrical data — voltage, current, power factor, kWh, and more.But there was one problem: all this information stayed within the meters. Operators had to manually read each display, record data into logs, and compile spreadsheets at the end of the day.By the time analysis was done, the energy had already been wasted. The factory needed a real-time, automated system to collect, process, and visualize energy data from multiple meters spread across the site.
Our Solution
The Turning Point: Deploying SEDAC Volkkommen deployed SEDAC, a powerful Modbus-to-MQTT IoT gateway built for seamless data acquisition from industrial energy meters.SEDAC unit connected to a cluster of Modbus-enabled energy meters installed at the main LT panels, dryers, and boiler sections. SEDAC collected instantaneous readings — including: Voltage (V) Current (A) Active and Apparent Power (kW/kVA) Energy (kWh/kVAh) Power Factor Maximum Demand Using MQTT protocol, SEDAC transmitted this data securely to V-VAC IoT platform, where the engineering team could visualize energy usage live — on a single dashboard. Inside SEDAC: The Digital Bridge At the core of SEDAC lies a robust Modbus master engine that polls multiple meters simultaneously, aggregates the data, and forwards it wirelessly over LoRa or Wi-Fi, depending on site conditions. The gateway ensures bi-directional communication, meaning it doesn't just collect data — it can also transmit control or configuration commands back to devices when needed. The plant team could now: Monitor machine-level energy consumption in real time. Compare load performance during peak and off-peak hours. Identify inefficiencies in boilers and drying lines. Receive alerts if power factor or load imbalance crossed limits. Generate automated daily and monthly energy reports. With SEDAC, energy data became visible, actionable, and reliable — all without changing the existing metering infrastructure.
Key Results
The implementation delivered measurable improvements across operations, efficiency, and cost reduction:
The Results: From Guesswork to Data-Driven Savings
In just weeks, the impact was measurable:
25% improvement in overall power factor, reducing utility penalties.
Energy consumption reports revealed inefficiencies during low-production hours.
Real-time monitoring helped prevent motor overloads and tripping incidents.
Data-driven scheduling optimized the use of dryers and conveyors.
The management finally had the visibility they needed to make informed decisions — cutting unnecessary energy use without affecting production quality.
The Impact: Brewing a Smarter Operation
What once required manual note-taking now runs autonomously, powered by SEDAC's intelligent communication.Today, the factory management starts each day by checking their V-VAC dashboard, seeing real-time trends in energy usage, machine efficiency, and overall power health.
With SEDAC, the factory didn't just install a gateway — they built a digital foundation for energy management, connecting every meter, every process, and every decision.
At Volkkommen Industries, this deployment stands as a model for how IoT gateways can modernize traditional industries, empowering them to achieve sustainability and operational excellence — one watt at a time.