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 MTK connected its entire electrical installation, fluid networks (gas with volume correctors, steam, water, compressed air) and production lines to the EnergySave platform, to automatically calculate production KPIs and structure its ISO 50001 certification journey.
Manufacture des Tabacs de Kairouan (MTK), alongside the Régie Nationale des Tabacs et des Allumettes (RNTA), is one of the two major operators in Tunisia's tobacco sector, responsible for operating the national tobacco fiscal monopoly. Based in El Mansoura, Kairouan, the manufacturing plant produces several recognized cigarette lines widely established on the market, including Cristal, Caravane, and Saphir.
The plant combines a dense, high-capacity electrical infrastructure (main incoming MV/LV feeders, workshop distribution panels, automated backup generator sets, air handling units, and industrial compressors) with multiple critical utility networks: high-temperature natural gas, industrial steam, hot process water, condensate return circuits, chilled water, and continuous compressed air.
The Core Challenge: As part of its structured path toward ISO 50001 certification (Energy Management Systems), MTK required a centralized IIoT solution to reliably measure all energy vectors across the facility, establish real-time telemetry with production machines, and automatically calculate energy performance indicators against output volumes without manual re-entry.
To fulfill MTK's operational and ISO 50001 requirements, EnergySave by DIDAMIND deployed an end-to-end multi-vector monitoring architecture:
Multi-level sub-metering across main incoming feeders (1 to 6B), workshop distribution panels (confection, packaging, boiler room, HVAC), automated emergency generators (GEG 1-4), compressors, and air handling units (CTA).
Integration of 2 VEMMTEC IGTM turbine flow meters paired with MacBat 5 volume correctors (Bono and Mingazzini gas stations) for PTZ-compensated gas metering, alongside 1 Kobold DVH steam flow meter.
4 Optiswirl 4200 vortex flow meters on hot water and condensate return loops, plus 3 Optisonic 6300 ultrasonic flow meters on chilled water networks (Ext. 1, Ext. 2, Int. 1).
Dedicated VA500 thermal mass flow meters installed on compressors 1, 2, 3, and 4 to accurately monitor compressed air generation and isolate pneumatic losses.
Real-time MCHPROD1 machine integration covering the 3 primary cigarette lines, precision weighing/dosing stations per blend (Masse Variété 1, 2, 3), and prototype confection.
Automated calculation of energy intensity ratios per manufactured unit, supported by DIDAMIND's specialized training session on ISO 50001 management standards.
A direct look at the physical sensor hardware installed across MTK's factory floor — connecting main electrical distribution switchboards, natural gas turbine meters with electronic volume correctors, thermal air flow meters, and high-pressure steam meters into the EnergySave IIoT gateway network.
Installed in main incoming MV/LV feeders and workshop power distribution cabinets.
Turbine flow meter paired with continuous PTZ electronic volume corrector on Bono boiler line.
High-precision turbine gas metering and PTZ volume correction on Mingazzini boiler line.
Real-time Nm³/h flow and consumption metering on compressor discharge lines.
Vortex mass flow measurement on primary steam generation and distribution lines.
Connecting 67 multi-utility points and manufacturing machinery within EnergySave brings transformative operational advantages for MTK:
Single pane of glass unifying electricity, compensated natural gas, steam, hot water, chilled water, and compressed air.
Direct machine telemetry computes specific energy consumption per produced cigarette batch with zero manual input.
Instant alerts pinpointing boiler thermal drifts, gas excess, compressed air leaks, and peak off-hour loads.
Reliable, timestamped baseline data fulfilling the strict auditing criteria of international Energy Management Systems.
Clear analytics dashboards providing technical and operational teams with actionable insights for continuous optimization.
"Working with DIDAMIND on this energy monitoring project improved our visibility into energy use, helped identify inefficiencies, and strengthened our decision-making — while laying the groundwork for our ISO 50001 journey."
By combining high-frequency IoT multi-energy sub-metering with direct machine production links, MTK continuously refines its energy performance, eliminates utility waste, and reinforces its ISO 50001 governance.
Deployment Validation: Technical scope based on the connected equipment inventory verified on the EnergySave by DIDAMIND platform (67 metering points: 46 power meters, 7 production feeds, 4 air flow meters, 4 water meters, 3 chilled water meters, 2 gas volume correctors, 1 steam meter).
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