Vossloh Cogifer Polska Ltd., a manufacturer of modern railway, tramway, and metro track systems—including turnouts, rail crossings, control and signaling devices —undertook a project to implement an integrated utility consumption analysis system (MCA5tech) across its 16-hectare production facility. Given the distributed nature of the metering infrastructure and the need for centralized data management, the company opted for the scalable MCA5tech solution.
This system enables comprehensive utility and energy management while supporting the plant’s alignment with the requirements of the ISO 50001:2018 energy management standard.
Scope of Implementation
The project was delivered by Eco5tech S.A. (a joint-stock company), which installed four MCA5tech metering units at strategic points within the plant infrastructure. Each unit is connected to a central server-based application operating within the plant’s local network.
The system communicates with the metering devices using Modbus RTU and Ethernet protocols, ensuring seamless data integration and bidirectional communication. To monitor electricity consumption, three-phase energy meters were installed, supported by current transformers appropriately selected for the load profiles of individual plant sections.
Parameters are recorded from machines, production lines, medium-voltage (MV) substations, transformers, and the main gas metering point.
Data from the gas meter is collected via an intrinsically safe telemetry circuit, in compliance with standards for explosive hazardous zones.
MCA5tech System Structure:
#1 – MV substation + precision machining lines,
#2 – second MV substation + high-power machine tools
+ compressed air station,
#3 – transformers + main gas meter,
#4 – monitoring of auxiliary utility sub-meters.
Implementation Outcomes
The system centralizes metering data, enabling remote access and reading from a single location. Maintenance department staff receive automated daily reports.
Strategic Importance
The MCA5tech system is a key tool for implementing the plant’s energy policy. It ensures compliance with ISO 50001:2018 requirements and provides valuable data for ESG reporting.
A standardized utility metering structure supports transparency and enables scalable system expansion in line with the plant’s growth.
Implementation results:
- automation of data acquisition,
- minimization of errors resulting
from manual intervention, - increased precision of detection
of deviations and failures, - ability to conduct analysis in real time.