Power Quality & Energy Management
Power quality and energy management (PQ&EM) play a critical role behind the scenes, but many operations fail to recognize how these areas impact their production lines.
Power Quality and Energy Management Services
Malisko designs and deploys systems for monitoring power quality and energy consumption. These systems can help manufacturing teams identify surges, root causes of excess use and more. Our team specializes in monitoring for all types of power — water, air, gas, electricity and steam. Our expertise covers areas such as:
- Monitors for quality, harmonics, waveforms and flicker
- Dynamic electrical power sag correction and notification
- Flow, pressure and temperature meters for water, gas and air
- Web-enabled tools to capture, store, analyze, correlate, manage and share energy data
- Power conditioning for improving true power factor, reducing harmonic distortion and reducing voltage notching
The Advantages of Power Quality and Energy Management
Power quality and energy management solutions lead to major advantages for manufacturing operations, including:
- Reduced costs: Poor power quality and energy management may lead to higher energy costs that add up over time. With PQ&EM automation, you can leverage data to improve energy usage and reduce energy costs significantly. Based on Energy Star’s research, most companies can achieve about a 10% reduction in energy with energy management solutions. Consider how this reduction will save your operation money.
- Minimized risk: Sensitive equipment can fail with poor power quality, leading to more downtime and a higher rate of equipment replacement. PQ&EM solutions can identify changes in performance and show your operation how to act to minimize these risks.
- Increase efficiency: When your equipment operates smoothly, your output improves. Our PQ&EM solutions can help you improve efficiency over the long term. Studies on the oil and gas industry have uncovered that digital technologies like PQ&EM could boost the discovery of oil and gas resources by 5%.
Power quality and energy management (PQ&EM) play a critical role behind the scenes, but many operations fail to recognize how these areas impact their production lines.
Power Quality and Energy Management Services
Malisko designs and deploys systems for monitoring power quality and energy consumption. These systems can help manufacturing teams identify surges, root causes of excess use and more. Our team specializes in monitoring for all types of power — water, air, gas, electricity and steam. Our expertise covers areas such as:
- Monitors for quality, harmonics, waveforms and flicker
- Dynamic electrical power sag correction and notification
- Flow, pressure and temperature meters for water, gas and air
- Web-enabled tools to capture, store, analyze, correlate, manage and share energy data
- Power conditioning for improving true power factor, reducing harmonic distortion and reducing voltage notching
The Advantages of Power Quality and Energy Management
Power quality and energy management solutions lead to major advantages for manufacturing operations, including:
- Reduced costs: Poor power quality and energy management may lead to higher energy costs that add up over time. With PQ&EM automation, you can leverage data to improve energy usage and reduce energy costs significantly. Based on Energy Star’s research, most companies can achieve about a 10% reduction in energy with energy management solutions. Consider how this reduction will save your operation money.
- Minimized risk: Sensitive equipment can fail with poor power quality, leading to more downtime and a higher rate of equipment replacement. PQ&EM solutions can identify changes in performance and show your operation how to act to minimize these risks.
- Increase efficiency: When your equipment operates smoothly, your output improves. Our PQ&EM solutions can help you improve efficiency over the long term. Studies on the oil and gas industry have uncovered that digital technologies like PQ&EM could boost the discovery of oil and gas resources by 5%.
Frequently Asked Questions About Smart Manufacturing
Still have questions about smart manufacturing? We can answer them.
What is manufacturing intelligence and how is it different from regular reporting?
Smart manufacturing applies the Industrial Internet of Things (IIoT) to the production process. Manufacturing intelligence goes beyond static reports. It involves continuously collecting, contextualizing, and presenting operational data in ways that support real-time decisions. Where traditional reporting tells you what happened after the fact, a well-designed manufacturing intelligence system tells you what is happening now — and often why — so your team can act before a problem becomes a loss.
Do we need to replace our existing control systems to get started?
Not necessarily. Malisko specializes in integrating manufacturing intelligence solutions with existing infrastructure — including legacy historians, PLCs, DCS systems, and ERP platforms. In many cases, the data you need is already being collected; the gap is in how it is structured, presented, and made available to the people who need it.
How long does a manufacturing intelligence project typically take?
Project timelines vary based on scope, the number of data sources being integrated, and the complexity of the reporting requirements. A focused dashboard or reporting project for a single line or facility can often be completed in weeks. Enterprise-scale deployments across multiple sites are phased over several months. Malisko works with you during the front-end design phase to define scope and set realistic project timelines. The easiest way to start with smart manufacturing is to partner with a company that offers a full suite of automation and IoT services, such as Malisko.
Can manufacturing intelligence solutions be accessed remotely or on mobile devices?
Yes. Modern manufacturing intelligence platforms support web-based and mobile access, allowing managers and executives to view production KPIs, alerts, and reports from anywhere. Malisko designs solutions with your access requirements in mind, whether that means plant-floor displays, office dashboards, or remote mobile access.
What is the difference between a DCS and a PLC-based control system?
A Distributed Control System (DCS) is designed for complex, continuous process applications — think chemical plants, pharmaceutical manufacturing, or large food and beverage facilities with many interdependent control loops. DCS platforms excel at managing hundreds or thousands of I/O points with tight integration between control, alarming, and historian functions. PLC-based systems (often combined with SCADA) are more common in discrete and hybrid manufacturing environments where the emphasis is on machine-level control and sequencing. Malisko has expertise in both architectures and can help you determine which approach best fits your process requirements.
How disruptive is a DCS migration? Can we do it without shutting down production?
Migration complexity depends on the size of your system, the criticality of the process, and the gap between your existing platform and the target architecture. Malisko uses a structured migration methodology that prioritizes production continuity — including parallel operation strategies, phased cutover plans, and thorough simulation and testing before any live changes. Many migrations can be executed during planned maintenance windows, minimizing impact on production schedules.
Can Malisko help us make the business case for a process automation investment?
Yes. We regularly support clients in building the justification for automation projects, including ROI modeling, energy savings projections, downtime cost analysis, and compliance risk assessments. A front-end engineering design (FEED) engagement is often the right first step — it gives you the engineering detail needed to develop an accurate capital estimate and a clear picture of the expected return.
Experience the Power of PQ&EM With Malisko
Malisko’s tailored solutions drive ROI and help operations improve efficiency. See what our team can do, and contact us today to get started on your PQ&EM project.
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