Real-time monitoring of energy use for greener machining workshops

The high-energy demand of modern machining processes remains a critical challenge in building more sustainable production chains. In recent years, tracking machine power usage has become a common strategy to reduce companies’ environmental footprint. However, these effects often focus on the life cycle assessment (LCA) of individual processes rather than the broader impact of the entire workshop. Energy consumption, though, extends beyond core machining tasks to include the whole production environment, such as auxiliary power tools and electrical appliances, air compressors required for the proper functioning of the facility, and the overhead lighting systems of the facility. To address this, a real-time monitoring system named Rainforest Corner was developed. Its purpose is to detect inefficient or unnecessary energy use and support more responsible resource management, ultimately reducing the workshop’s environmental footprint. The system features a central screen, a traffic-light indicator, and a foliage display. Depending on current energy usage, the light glows green, yellow, or red, while an automated watering system activates accordingly. This design provides a tangible representation of the centre’s impact on the environment and encourages greater awareness of sustainable practices among staff. Since its introduction, Rainforest Corner has contributed to a measurable reduction in annual energy use, with consumption falling by 60% from 519 MWh in 2019 to 207 MWh in 2024. These results highlight how accessible monitoring tools can drive meaningful progress toward greener manufacturing.