EnergySave by DIDAMIND is the leading cloud-based industrial energy management platform. Monitor, analyze, and optimize your assets in real time.
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EnergySave by DIDAMIND is the leading cloud-based industrial energy management platform. Monitor, analyze, and optimize your assets in real time.
How Crown Maghreb Can, a key manufacturing subsidiary of Crown Holdings, Inc., manages 109 digital power meters, 12 smart ambient sensors, 7 water meters, 6 gas meters, and its industrial compressor fleet within a unified IIoT hypervision platform.
Located in the industrial area of El Agba, Tunis, the Crown Maghreb Can manufacturing facility is a premier production center for Crown Holdings, Inc. in North Africa. Following significant expansion investments, the plant operates at ultra-high speeds via the Draw and Wall Ironing (D&I) process to manufacture over 1.2 billion aluminum beverage cans per year.
Operating at such extreme production cadences creates intense, multi-vector utility demands: heavy electrical loads for cuppers, bodymakers, and high-speed conveyors; continuous high-volume compressed air for contact-free can transfer; high-temperature natural gas for Inside Bake Ovens (IBO), Pin Ovens, and Dryers; and an extensive hydraulic network buffered by a 500 m³ industrial water storage tank.
The Main Challenge: The engineering objective was to interconnect all 144 heterogeneous industrial assets across the multi-acre plant without interrupting production, unifying power, natural gas, water, compressed air, temperature, humidity, and solar generation into a single real-time, auditable platform.
To implement this massive IIoT architecture, EnergySave by DIDAMIND deployed an industrial communication backbone powered by intelligent SmartBox Edge gateways (Modbus RTU/TCP), ensuring reliable high-frequency data ingestion:
Complete multi-level instrumentation across MV/LV substations (TR1 & TR2), main and power distribution panels (PDP/SDP), filter banks, and individual production machinery with dynamic Sankey visualization.
Live monitoring of Kaeser rotary screw compressors at 7 bar, tracking airflow, power, load factors, and automated runtime countdowns for predictive wear parts (lubrication, air/oil filters, valves, motor bearings).
3D Hydraulic SCADA synoptic, continuous level tracking of the 500 m³ water reserve, booster pump control, and strict zero-flow verification on the fire protection network (RIA) to eliminate leaks.
High-precision thermal monitoring for the Inside Bake Oven (IBO), Washer Dryer 11, exterior Pin Ovens 1 & 2, and the industrial steam boiler.
Strategic thermo-hygrometric mapping safeguarding critical electrical drives, inverters, and heavy motors against summer thermal stress and overheating.
Rooftop solar PV monitoring, performance ratio calculation, and real-time synchronization with factory load profiles to maximize on-site self-consumption.
Connecting 144 industrial assets within EnergySave delivers critical operational advantages for Crown Maghreb Can:
Plant Management, Energy, Production, and Maintenance departments share the exact same synchronized real-time data across all utility vectors.
Granular sub-metering instantly isolates compressed air leaks, oven thermal drifts, water line losses, or off-production electrical baseloads.
Hourly wear tracking on compressed air machinery and ambient alerts safeguard continuous high-speed canning operations.
Instant generation of auditable energy and carbon accounting reports aligned with international Crown Holdings, Inc. corporate standards.
"The scale of deployment achieved with EnergySave at our Crown Maghreb Can facility is remarkable: interconnecting 144 assets — including over 100 power meters, gas ovens, compressors, and hydraulic networks with 3D SCADA synoptics — provides unmatched operational mastery. It has become our essential tool for running a world-class plant."
By merging multi-utility telemetry with real-time environmental monitoring, Crown Maghreb Can continuously optimizes aluminum can manufacturing efficiency, safeguards sensitive drives, and consolidates its regional packaging leadership.
Deployment Validation: Operational deployment verified on the EnergySave by DIDAMIND platform (144 connected assets: 109 power meters, 12 ambient sensors, 7 water meters, 6 gas meters, compressor SCADA, 500 m³ tank management, and solar PV).
Join Crown Maghreb Can and 200+ connected industrial sites across the region. Adopt comprehensive IIoT hypervision and take absolute control of your consumption today.
