Terex (Dungannon) recognises the critical importance of minimising energy consumption.

Terex is a global manufacturer of materials processing machinery and aerial work platforms. Terex design, build and support products used in construction, maintenance, manufacturing, energy, recycling, minerals, and materials management applications. 




Some of Terex’s products and solutions enable their customers to reduce their impact on the environment, these include electric and hybrid product offerings that deliver quiet and emission-free performance, products that support renewable energy, and products that aid in the recovery of useful materials from various types of waste. Terex has products that are manufactured in North America, Europe, Australia, and Asia and sold worldwide. They  engage with customers through all stages of the product life cycle, from initial specification and financing to parts and service support.
Terex is a substantial user of energy, from electricity to fossil fuels. Terex sought to lower the effects of escalating energy costs and enhance sustainability. After attending our workshop on an introduction to the Smart Manufacturing Data Hub the company reached out to our BDO team for support on monitoring their energy consumption.
Terex was interested in exploring ways to use current data available to them to better understand when, where and how energy was being used, as well as to identify opportunities for reduction.


Terex and SMDH conducted an energy consumption investigation, capturing data on usage, shift patterns, and tariffs. The information was uploaded to the Manufacturing Data Exchange Platform, enabling Terex to analyse visual dashboards and extract insights for factory improvements.

A base load was established, categorising usage beyond the threshold during non-working hours as "phantom load" and exceeding the base load during working hours as "working load." The analysis revealed an 8.00 am peak in energy consumption, gradually decreasing throughout the day. Examining one year of data, SMDH found that 17% of Terex's energy fell under "phantom load," mostly occurring on weekends and mornings due to a high base load and extended working hours.

Daily energy comparisons showed higher consumption on Saturdays than Sundays, prompting Terex to explore additional energy conservation measures. Terex's dashboard features a 'Comparison view' to identify abnormalities between date ranges and an "Intervention Advice" page detailing critical graphs and recommending steps for energy reduction.

SMDH suggested training employees to switch off unused equipment among other recommendations. Terex continues to use the dashboard to monitor the ongoing impact of energy management activities.





Fig 1
1  Sample Data Chart for Phantom Load Terex
Identifies 17% Phantom Load.
Chart shows total consumption KWh over the period. 
Showing the daily consumption of energy. Easy to compare and identify trends
Fig 2
2 Baseline energy & phantom load over non-working days. (Sample data)
Fig 3
3 Comparing Data over two date ranges. (Sample Data) 
Using the data comparison tool shown in Figure 3, Terex were able to identify how much energy is consumed during periods of factory close time.  They identified almost a third of their energy costs are used during periods of close time.


The solution provided to Terex enables them to investigate their energy usage and would also allow the company to compare their energy consumption across other manufacturing sites. They were impressed with the dashboard and the information provided.

As a result of the initial SMDH energy project Terex have decided to embrace other appropriate sensor solutions, like power monitors - which can harness data from individual machinery’s power consumption and enhance the existing energy use data insights for Terex.

Terex intends to use their energy insights data to contrast and compare machinery in their factory and between sites.

For more information: New Energy Insights for Manufacturing SMEs - at the Smart Manufacturing Community Resources

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