The September bill
It looks like any other month.
₹16,99,845 across seven lines. Nothing on the page says which rupees you could have kept.
On-premises Energy Monitoring System Catch the penalty
before the bill does.
KONDUKTOR® EMS watches every connected meter in real time, so load spikes, poor power factor and idle loads get caught before they show up on your bill.
On-premises
Works without Internet
Any meter brand
Mobile & desktop apps
Encrypted remote access
What is your electricity bill doing to you?
- MD penaltyOne spike sets the whole month’s demand charge.
- Power factor and kVAhEvery unit costs more below unity power factor.
- Machines left idleEnergy spent with nothing made.
- Solar, DG and gridEvery source against the load, and what a DG unit really costs.
- Which panel runs up the billKnow which panel, department or tenant used what.
- Contract DemandSet too high, you pay every month. Too low, you pay in penalties.
01 The cost you see too late
Your electricity bill tells you what happened. KONDUKTOR® EMS shows you while it is happening.
By the time the monthly bill arrives, the costly moments behind it are already over. Scroll through one ordinary bill and see what each line was hiding.
HT electricity billSample bill
Sep 202630 days
- Demand charges500 kVA₹1,95,000
- Excess demand60 kVA₹46,800
- Energy charges1,87,000 kWh₹22,900 wasted₹13,09,000
- Peak-hour surcharge+15%₹31,200
- Power factor surchargePF 0.87₹18,400
- Fixed charges₹18,500
- Electricity duty5%₹80,945
Total payable₹16,99,845
Behind this bill1 to 30 Sep
Load through the month · kVA
- Excess demandSheds load before CD₹46,800Automatic
- Idle and Sunday energySwitches off idle machines₹22,900Automatic
- Peak-hour surchargePauses loads in peak hours₹31,200Automatic
- Power factor surchargeWarns your team to act₹18,400Team alert
Avoidable so far₹0
₹46,800 Excess demand
One morning went over Contract Demand.
Day 15 touched 96% and nobody saw it. On Day 24, heavy motors started together at 11:42 and demand reached 560 kVA.
₹22,900 Hidden inside energy
Power paid for while nothing was made.
At 02:20 Machine 2 still drew 6.2 kW with production at zero. Four shut Sundays used another 856 kWh.
₹31,200 Peak-hour surcharge
Heavy loads ran at the costliest hour.
At 19:30 the plant was close to full load inside the peak window, when every unit costs 15% more.
₹18,400 Power factor surcharge
Power factor slipped every afternoon.
Motors pulled PF down to 0.84 at 14:30, under the 0.90 limit. The month closed at 0.87.
Month-end
₹1,19,300 was avoidable.
Each of these showed up on the day it happened. KONDUKTOR® EMS catches it as it forms, then acts through Modbus I/O cards, engineered for your plant as part of your project.
See this on your own bill02 Protect your energy cost
One system. Seven ways to act sooner.
Move beyond recording consumption. See the operating conditions that influence penalties, waste and production efficiency.
Maximum Demand
Reduce demand penalty risk
Track Running Maximum Demand against Contract Demand. Colour-coded warnings give your team time to respond.
Power Factor
Improve power factor
Locate poor PF conditions, identify affected feeders and evaluate the required correction—including capacitor-sizing guidance.
Idle Detection
Eliminate idle energy waste
See when equipment is running, idle, stopped or overloaded—and estimate non-productive consumption.
Time-of-Day Tariff
Reduce peak-hour cost
Identify loads operating during expensive TOD periods and evaluate opportunities to shift them.
Contract Demand
Right-size Contract Demand
Use historical MD patterns to evaluate whether booked demand matches the plant’s actual requirement.
Specific Energy Consumption
Improve energy per unit
Track Specific Energy Consumption and compare production efficiency across operating periods.
Before and after
Verify every energy decision
Compare shifts, days, feeders and historical operating patterns before and after corrective action.
See decision-ready analytics →03 Alerts and automatic control
Don’t just record the problem. Catch it early, then act.
Set alerts for demand, power factor, voltage, current and meter communication, and let each machine’s own history set its limits. Then let the system act: shed load before CD, pause loads in peak tariff hours, switch off idle machines and hold solar export at zero where the inverter allows it.
Main incomer · kVA01 Oct
Event log
A green dot means the system acts on its own through Modbus I/O cards, engineered for your plant as part of your project. See demand control
- Manual override
- Every action logged
- Fail-safe if communication drops
04 Analytics and reporting
Turn meter readings into management decisions.
Understand where, when and why energy performance changes—not just the final kWh total.
Load heatmap
See, in 15-minute or hourly blocks, the times and days when factory demand is consistently highest.
Shift comparison
Compare consumption across production shifts and operating schedules.
Maximum Demand history
Review long-term MD patterns for demand planning and Contract Demand decisions.
Estimated electricity bill
Review energy, demand, TOD, fixed charges and tariff inputs before the official bill arrives — see where load shifting could cut cost.
Excel and CSV reports
Export meter, billing and historical data for finance reviews, audits and analysis.
Monthly emissions tracking
Track monthly CO₂-equivalent alongside energy use for internal sustainability reporting.
05 Why on-premises
Why on-premises monitoring makes sense for your factory.
Cloud convenience comes with trade-offs.
Cloud platforms can simplify remote access, but they can also introduce Internet dependency, off-site data storage and less control over operational history. KONDUKTOR® EMS keeps core monitoring inside your factory while providing secure remote access when required.
IIoT energy monitoring that stays inside your plant: your meters, your gateway, your data — no cloud server in between. See how an on-premises energy monitoring system works.
Your plant network
DISCOM supply
Main LT panelIncomer + feeders
KONDUKTOR®EMS
Production shedMachines
KONDUKTOR®EMS
UtilitiesCompressor, pumps
KONDUKTOR®EMS
+ Next panelAdd a gateway when you're ready
+Plant WiFi
Secure remote access
One screen, every panelPhone · tablet · PCIntranet or internet
Plant 2Data stays on sitePlant 3Data stays on site+Next plantAdd when you're ready
- Up to 10 meters per gateway
- Each gateway logs on its own
- No server PC in between
Why it stays inside
Your plant data leaves the plant
Energy patterns can reveal production schedules, machine utilisation and operating volumes. KONDUKTOR® EMS keeps this information within your plant network.
Monitoring depends on connectivity
Cloud outages can interrupt access. KONDUKTOR® EMS continues monitoring, logging and alerting locally—even when the Internet is unavailable.
More external exposure
On-premises monitoring reduces unnecessary online accounts, connections and external systems that must remain secure.
The vendor decides how much detail survives
Many cloud platforms average raw readings down to hourly or daily summaries as they age. Local storage and backups keep yours at full detail, for as long as you choose.
History becomes platform-dependent
KONDUKTOR® EMS keeps records locally accessible and exportable, reducing dependence on a cloud platform.
Remote access without cloud dependency
Access through an encrypted Zero Trust network—without opening router ports or exposing the dashboard to the public Internet.
Cloud convenience where useful. On-premises control where it matters.
06 Built for factories
Plant data stays close to the plant.
Controlled industrial access, local records and dependable operation for day-to-day monitoring.
Role-based access
Admin, Operator and Viewer levels protect settings and plant information.
Local backups
Download reports and retain backup copies of important operational records.
Secure updates
Signed software and firmware updates help protect system integrity.
Device-side alert history
Alert records remain available even when the monitoring browser is closed.
Storage-health visibility
Monitor gateway storage status before capacity becomes a surprise.
Core operation stays local
Dashboard access, logging and alerts continue without continuous Internet dependency.
07 Mixed-meter ready
Works with the meters you already have. No brand lock-in.
Up to 10 meters per gateway, mixing brands and single-phase/three-phase models on one shared Modbus RTU bus. Need more? Add a gateway for the next panel — no server PC, nothing to replace.
- Any Modbus RTU meter, any brand
- No replacing meters already installed
- Mirrors your single-line diagram: incomer, feeders, sub-panels
- Main-feeder and panel-level views
- Multiple gateways, one plant-wide view
01Schneider Electric
02Secure Meters
03Lauritz Knudsen (formerly L&T)
04Rishabh Instruments
05Selec Controls
06Chint Electric
07HPL Electric & Power
08Elmeasure India
09Siemens
10ABB
Or any MFM with Modbus RTU — share the exact meter make and model and we'll map the protocol and registers before installation.
Start with your incomer. Grow to every panel.
- 01Incomer
One meter on the main supply: bill, Maximum Demand, PF and penalty alerts from day one.
- 02Main panels
Feeder-wise meters show where the energy goes, panel by panel.
- 03Every machine
Idle loads, shift-wise use and cost per unit made, machine by machine.
- 04Every plant
Plants in other cities join one dashboard and one combined report. Each keeps its data on site.
Add gateways as you grow. Each one reads its own panel, so the plant never slows down.
08 Built for every energy decision-maker
One system. Clear value for every team.
Factory owners
From Contract Demand crossings to PF savings, at a glance across every panel.
- Avoidable energy cost
- Penalty risk
- Plant-wide performance
Plant heads
See which panels are running, idle or stopped across every shift, every day.
- Idle machines
- Shift comparisons
- Downtime
- Load patterns
Electrical teams
Live per-phase readings, with instant alerts the moment a threshold is crossed.
- Maximum Demand
- PF
- Voltage
- Current
- Overload
- Meter health
Finance teams
Reconcile every DISCOM bill against actual meter data before you pay it.
- Bill estimates
- Contract Demand review
- Reports
- Audit trail
Energy managers
Spot waste patterns across days, shifts and seasons, not just this month's bill.
- SEC
- Load factor
- TOD analysis
- Heatmaps
- Historical trends
Sustainability teams
Ready numbers for ESG disclosures and sustainability audits.
- Monthly CO₂-equivalent tracking
- Energy reporting support
For plants everywhere.Previously
- Maruti Suzuki
- Tata Motors
- Eicher Polaris · Royal Enfield
- SolarSquare
- Industrial automation: PLCs, robots & machines
- Breakdown resolution & recurrence prevention
- Plant energy management
- IoT product development
- Procurement & cost control
“Many breakdowns I fixed had already shown up in the meters. Nobody was listening.”
For 10 years I kept plants running — paint-shop robots and PLCs at Maruti Suzuki and Tata Motors, maintenance in-charge of the weld shop at Eicher Polaris, then energy and IoT projects at Royal Enfield. At Maruti the paint shop ran about 1,750 vehicles a day; at Tata Motors I kept uptime above 96%. At Eicher Polaris I traced a recurring engine fuel pump failure to its root cause in an hour and proposed the fix that ended it — one the teams involved had struggled with for a year. Along the way I built a fault diagnostics system on shop-floor HMIs and designed a robot atomising bell testing kit that won a national design award.
Across these years I also delivered major energy-saving projects. Each one taught me the same lesson: a plant can only cut the energy it can see. And seeing it means knowing what every unit was worth — how much went into production, and how much was simply wasted.
In maintenance, fixing a breakdown is only half the job. The other half is finding the root cause so it never comes back — and that needs a record of what the machine was doing before it failed. At every plant, the warning signs were in the meter readings, but no one was making sense of them.
Then for 7 years I led purchasing at SolarSquare, building its procurement and logistics team and managing about ₹350 crore of spend a year. There, every rupee had to show a return. I built KONDUKTOR® EMS end to end in-house on that rule: every reading becomes a decision with a price on it — what to shift, what to fix, and what each one saves.
09 Straight answers
Before you connect.
Does KONDUKTOR® EMS work without the Internet?+
Yes. The gateway keeps reading your meters, recording data and raising alerts with no Internet at all, and the dashboard opens on any phone or laptop on the plant network. Internet is needed only for access from outside the plant and for remote software updates.
What happens during a power cut?+
Recorded data stays safe, and the battery-backed clock keeps time — logging restarts on its own when power returns. Any energy the meters counted meanwhile is filled in as estimated, so totals still match the meter.
Will it work with the meters we already have?+
Usually, yes. Any multifunction meter with a Modbus RTU (RS-485) port can connect — up to 10 per gateway, any brand, single- or three-phase, on one shared cable. Send us the exact make and model and we will confirm the register map before installation. A meter without an RS-485 port cannot be read directly; we will tell you upfront.
We have more than 10 meters. Will it work?+
Yes. Add a gateway for every 10 meters, usually one per panel. Each gateway reads and records its own meters on site, and all of them appear in one dashboard and one panel hierarchy, with no server PC in between.
We have plants in different cities. Can we see them all in one place?+
Yes. Each plant gets its own gateways, and its data stays on site in that plant. Over the same encrypted Zero Trust network used for remote access, every plant appears in one dashboard. Head office can check each plant panel by panel, and pull one combined energy and bill report across all plants, with no cloud server in between.
Can we see the dashboard from outside the plant?+
Yes, on your phone or laptop, from anywhere. Access runs over an encrypted Zero Trust network, directly or through a secure relay, so no router ports are opened and the dashboard is never exposed to the public Internet. Only approved devices can connect, and the usual Admin, Operator and Viewer logins still apply.
Where is our data stored?+
On the gateway, inside your plant, with an encrypted backup on a computer in your plant. Nothing is sent to KONDUKTOR or to any cloud server.
Is KONDUKTOR® EMS an IIoT energy monitoring system?+
Yes. Gateways read the multifunction meters on your panels over Modbus RTU and show every reading live on a dashboard. Unlike most IIoT platforms, nothing is sent to a cloud: the readings, history and alerts stay inside your plant, and owners can still view them from anywhere over an encrypted private network.
Will it reduce our electricity bill on its own?+
It can. It warns as Maximum Demand approaches your Contract Demand, flags low power factor, peak-hour consumption and idle machines, and estimates the savings in rupees, so your team knows what to act on. With automatic control through Modbus I/O cards, engineered for your plant as part of your project, it also holds back chosen loads, avoids peak hours and switches off idle machines by itself. Actual savings depend on your tariff, your plant and the actions taken.
Is KONDUKTOR® EMS subscription-based?+
Yes. The subscription covers software updates, security fixes and technical support. If it lapses, monitoring and logging pause until it is renewed — history already recorded stays on the gateway and is not deleted.
Is there a warranty?+
Yes. The gateway carries a 1-year warranty against manufacturing defects.
10 Beyond monitoring
Solar. Machines. Control. One platform.
Monitoring is only the start. On the same system, KONDUKTOR® EMS goes three steps further.
Solar
Generation metered live against grid and load, and checked against today’s weather. A dusty string shows up the same day.
Machine health
Running, idle and stopped time for every machine, every shift. Overloads and imbalance flagged before they become breakdowns.
Control
Demand capped, peak hours avoided, solar and DG kept within limits, idle machines switched off. Through standard Modbus I/O, alongside your protection relays.
Start with the meters already installed
Your next avoidable energy cost may already be building.
See how KONDUKTOR® EMS can monitor your meters, reveal hidden energy waste and warn your team before costly conditions reach the electricity bill.
Meter compatibilityMonitoring pointsSuitable configurationLive product walkthrough
contact@konduktor.in