Global energy consumption has increased rapidly in recent decades due to industrial growth and expanding infrastructure, contributing to rising greenhouse gas emissions and climate change. However, many small and medium-sized industries still rely mainly on monthly electricity bills to monitor their energy usage, which provides delayed information but also makes it difficult to identify and correct energy inefficiencies in real time.
This paper presents the design and implementation of AeiX, an IoT-based real-time energy monitoring system that integrates energy meters, sensors, edge computing, and cloud analytics to provide continuous visibility into industrial energy consumption.
The system uses ESP32-based monitoring nodes equipped with voltage and current sensors to measure electrical parameters. Data is transmitted through the MQTT communication protocol to a time-series database (InfluxDB) and visualized using Grafana dashboards. A second prototype extends the system for industrial deployment using a Raspberry Pi connected to Modbus-enabled digital energy meters. A carbon analysis module converts energy data into estimated CO2 emissions using standard grid emission factors.
A pilot deployment in an industrial facility monitored energy for two weeks. It identified hidden nighttime compressor loads, leading to a 7.5% reduction in nighttime electricity consumption after corrective action. It also detected a malfunctioning capacitor panel through abnormal power factor readings, improving the power factor from 0.2 to 0.95 after repair.
This study demonstrates how a low-cost IoT monitoring platform can transform raw energy data into actionable sustainability insights. Continuous measurements and dashboard-based visualization enables industries to identify inefficiencies and take timely actions that improve energy efficiency and sustainability.
The architecture provides a scalable framework for future integration with predictive analytics and carbon accounting systems, supporting progress toward Net-Zero targets and UN Sustainable Development Goal 12: Responsible Production and Consumption.
Keywords:
Industrial IoT, Energy Monitoring, Smart Manufacturing, Carbon Tracking, Sustainable Energy Systems