ZF Serbia, Pančevo – Integrated Energy Management System for Sustainable Manufacturing
Project Overview
Customer: ZF Serbia d.o.o., Pančevo, Serbia
Industry: Automotive Manufacturing
Year of Realization: 2022
General Contractor: Energogroup d.o.o.
ZF is one of the world's leading automotive suppliers, continuously investing in sustainable manufacturing and energy-efficient production facilities. As part of its global energy management strategy, the company required a comprehensive solution capable of monitoring and analyzing both electrical and non-electrical consumption across its production facility in Pančevo, Serbia.
The Challenge
Modern manufacturing facilities face increasing pressure to reduce energy consumption, improve operational efficiency, and comply with stringent environmental regulations. One of ZF's key objectives was to establish a reliable basis for calculating the CO₂ footprint per manufactured product.
To achieve this goal, it was necessary to:
- Monitor all relevant energy flows and media consumption in real time.
- Collect detailed consumption data at every level of the production process.
- Integrate electrical and process-related measurements into a single platform.
- Provide transparency across the entire facility to support sustainability targets and future ESG reporting requirements.
The Solution
Together with our partners Janitza Electronics, Endress+Hauser, and Energogroup, ACE, ELTECH Group designed and implemented a complete (EMS) for the ZF Pančevo production plant.
The project scope included:
- Engineering and project evaluation
- Supply of hardware and software
- Installation and commissioning of all devices
- TCP/IP communication infrastructure
- Integration of all measuring points into a centralized platform
- Configuration and parameterization of the GridVis® software environment
- Integration with the plant's central SCADA system
The result was a fully integrated monitoring and energy management platform providing real-time visibility of energy usage throughout the facility.
Comprehensive Three-Level Electrical Monitoring
The Janitza solution was implemented across three operational levels:
Level 1 – Infeed Monitoring
Measurement and analysis of incoming power from the transformer substation to the production facility.
Level 2 – Distribution Monitoring
Monitoring of electrical distribution networks and feeders throughout the plant.
Level 3 – Machine-Level Monitoring
Detailed measurement of individual production machines and manufacturing processes.
This hierarchical approach enables complete transparency of energy flows from the plant entrance down to individual production assets.
Process and Utility Monitoring
In addition to electrical energy monitoring, the system integrated various process media using Endress+Hauser instrumentation:
- Heating and Cooling (HVAC)
- Compressed Air
- Water Consumption
- Thermal Energy
- Gas Measurement
- Solar Energy Systems
All measured values were consolidated within a single centralized platform, creating a unified view of the plant's complete energy ecosystem.
Centralized Data Management with GridVis®
The entire Energy Management System is operated through Janitza GridVis®, providing:
- Real-time energy monitoring
- Centralized data acquisition and storage
- KPI tracking and analytics
- ISO 50001 compliant energy management capabilities
- Web-based dashboards and reporting
- SCADA integration and connectivity with higher-level systems
- Advanced visualization and performance analysis tools
This enables plant management and engineering teams to make data-driven decisions based on accurate and continuously updated operational information.
Business Benefits
The implemented solution provides ZF with:
✅ Complete transparency of energy consumption throughout the facility
✅ Real-time monitoring of electrical and process-related parameters
✅ Accurate data foundation for CO₂ footprint calculation per product
✅ Improved identification of inefficiencies and energy losses
✅ Centralized management of energy and utility consumption
✅ Enhanced support for sustainability initiatives and energy optimization programs
✅ Readiness for future environmental compliance and reporting requirements
Conclusion
The ZF Pančevo Energy Management Project demonstrates how a modern manufacturing facility can successfully integrate electrical energy monitoring, utility metering, and advanced analytics into a single intelligent platform.
Through the collaboration of ELTECH Group, Janitza Electronics, Endress+Hauser, Energogroup and ACE, ZF Serbia now benefits from a comprehensive Energy Management System that supports operational excellence, sustainability objectives, and the long-term reduction of its carbon footprint.
This project stands as a strong reference for large-scale industrial energy management solutions and highlights Eltech Group's capability to deliver complex, future-oriented energy monitoring systems for global manufacturing companies.