Overview
A major manufacturing facility in Tijuana, Mexico, was operating two independent compressor rooms, each with its own compressed-air system. Legacy controllers installed over a decade earlier were still managing the equipment, but recent changes, including the addition of a new variable-speed compressor, were never integrated into the existing control setup. This created inefficiencies, inconsistent performance, and unnecessary energy waste.
Challenges
The plant faced several obstacles that were driving up operational costs and preventing alignment with its Industry 4.0 roadmap:
- A new compressor had been installed but not connected to the existing system controller, resulting in poor sequencing and avoidable energy consumption.
- Limited visibility across both compressed-air systems had led to gaps in maintenance and a lack of accountability.
- The facility required continuous performance tracking and integration of compressed-air data into a centralised digital architecture to support long-term efficiency goals.
Solution
To restore efficiency and create a unified, intelligent air-management environment, all compressors across both rooms were connected to the new Metacentre Core control platform. This enabled coordinated sequencing, consistent optimisation, and real-time responsiveness plant-wide.
Key elements of the solution included:
- Unified control across all compressors, replacing fragmented operation with a single intelligent system.
- 12-inch touchscreen interface, providing technicians with clear, local visibility into system status and performance trends.
- Full network integration, enabling real-time monitoring, analytics, and reporting via the plant’s LAN.
- Modbus TCP connectivity, allowing compressed-air data to flow into the facility’s Unified Namespace, supporting Industry 4.0 initiatives and enabling centralised analytics.
Results
The upgraded system delivered immediate and measurable improvements:
- 292,000 kWh energy savings per year
- 29,200 USD in annual cost savings (estimated)
- Enhanced accountability across teams due to transparent, continuous performance monitoring
- A modernised compressed-air infrastructure now aligned with the plant’s Industry 4.0 vision
Quote
“We’ve brought the facility’s compressor and system controls up to modern standards, delivering energy-efficient operation while providing full transparency and accountability. This supports the plant’s broader digital transformation strategy and ensures long-term performance.”
Below are a few site photos, plus Tibo from our Belgium office and William from our LA office, who were both on-site for the final connect and commissioning of the systems, along with the in-house team of the Mexican manufacturing facility.
