Introduction
In today’s industrial landscape, energy efficiency is no longer a luxury—it’s a necessity. Rising energy costs, regulatory pressures, and sustainability goals push manufacturers and chemical plants to find smarter ways to manage consumption. At Waltero, we’ve seen firsthand how LoRaWAN industrial sensors are transforming the way businesses track and optimize energy usage.
In this article, we’ll explore how LoRaWAN industrial sensors are reshaping energy management in manufacturing and chemical processing, real-world case studies of IoT-driven savings, and how Waltero’s retrofit smart metering solutions are making it easier than ever to upgrade legacy meters without costly replacements.
Defining LoRaWAN Technology
LoRaWAN technology enables wireless communication between devices in the Internet of Things (IoT) by serving as a Low Power Wide Area Network (LPWAN) protocol. It stands out for its ability to provide long-range, low-power, and low-cost wireless communication, making it an ideal solution for various IoT applications, including industrial automation, smart cities, and energy management.
One of the key advantages of LoRaWAN technology is its ability to enable connected devices to transmit data over long distances to a LoRaWAN network server. The system collects, analyzes, and utilizes this data for decision-making processes. The network server centralizes data collection, storing all transmitted data and preparing it for analysis. This capability is particularly beneficial for energy management, where real-time data insights can lead to significant cost savings and efficiency improvements.
In industrial settings, the ability to transmit data wirelessly over long distances without the need for extensive infrastructure makes LoRaWAN technology a game-changer. It allows for seamless integration of multiple devices, ensuring continuous data flow and enabling proactive management of energy consumption and other critical parameters.
The Energy Management Challenge in Industrial Facilities
The Hidden Cost of Energy Waste
For industrial operations, energy expenses can account for up to 40% of total production costs. However, many companies lack the tools to accurately track consumption patterns, leading to waste in areas like:
Idle Equipment Consumption: Machines running when not in use.
Unnoticed Leaks: Compressed air, steam, or gas leaks causing unnecessary energy drain.
Inefficient Scheduling: HVAC, pumps, and motors operating outside of optimal production times.
Reactive Maintenance: Energy spikes caused by equipment inefficiencies that go undetected.
Why Traditional Meters Fall Short
Traditional analog meters require manual readings—a slow, error-prone process that provides only a limited snapshot of energy usage. Without real-time data, industrial teams lack the ability to detect and respond to inefficiencies quickly.
This is where LoRaWAN smart meters come into play, enabling continuous monitoring and data-driven decision-making.
How LoRaWAN Technology Industrial Sensors Solve Energy Waste
LoRaWAN wireless technology offers versatility and applications across various sensor types, including industrial sensors, leak detection, temperature and humidity sensors, proximity sensors, push button sensors, and movement sensors. These sensors send alerts over a wireless network and provide critical real-time information, enhancing industrial and IoT solutions.
Traditional energy monitoring methods, such as manual meter readings or outdated analog meters, provide limited visibility into real-time consumption. This lack of insight leads to excessive energy waste, higher costs, and inefficiencies that go unnoticed for months. LoRaWAN smart metering is the answer—delivering granular, near real-time data that empowers industrial teams to make smarter decisions and drive energy savings.
What Makes LoRaWAN Ideal for Industrial Smart Metering? Extended Battery Life Applications
LoRaWAN (Long Range Wide Area Network) is an IoT connectivity technology that enables sensors to transmit small but critical energy data packets over long distances with ultra-low power consumption. LoRaWAN gateways play a crucial role in this process by facilitating communication and relaying data from end devices to a central network server or the internet. This makes it ideal for industrial environments where:
Meters are spread across large areas (factories, refineries, chemical plants, etc.).
Reliability is key—data must be transmitted even in harsh environments.
Battery life matters—LoRaWAN sensors can last 5–10 years without replacement.
Types of LoRaWAN Industrial Sensors
LoRaWAN industrial sensors are designed to provide high accuracy proximity detection, temperature, humidity, and other environmental data in industrial settings.
These sensors come in various types, each tailored to specific applications:
Humidity Sensors: These sensors measure the humidity levels in the air and are essential for monitoring conditions in warehouses, factories, and other industrial environments. Maintaining optimal humidity levels can prevent product spoilage and ensure the longevity of equipment.
Temperature Sensors: Temperature sensors are crucial for tracking temperature levels in industrial settings. They help in maintaining the right conditions for sensitive processes and materials, ensuring quality control and operational efficiency.
Proximity Sensors: Proximity sensors detect the presence of objects or people. They are widely used in production lines to monitor the presence of items, ensuring smooth operations and safety. In warehouses, they can help in tracking the movement of goods and personnel.
Vibration Sensors: Vibration sensors measure the vibration levels of machines and equipment. They are vital for predictive maintenance, allowing for early detection of potential issues in pumps, motors, and other machinery. By monitoring vibration levels, companies can prevent equipment failures and reduce downtime.
Each type of sensor plays a critical role in providing the data needed to optimize industrial processes, enhance safety, and reduce energy consumption.
How LoRaWAN Industrial Sensors Work
LoRaWAN industrial sensors operate by transmitting data to a LoRaWAN gateway, which then forwards the data to a LoRaWAN network server. This process ensures that the data collected by the sensors is centralized and ready for analysis. The network server plays a crucial role in data collection, analysis, and storage, making it possible to use the data for various industrial applications, such as energy management, location data tracking, and overall data collection.
One of the standout features of LoRaWAN industrial sensors is their extended battery life applications. These sensors are designed to operate for long periods without the need for frequent battery replacements, making them ideal for use in industrial settings where power sources may be limited or difficult to access. This extended battery life ensures continuous data transmission and reduces maintenance efforts.
By leveraging the capabilities of LoRaWAN technology, industrial organizations can gain real-time insights into their operations, enabling proactive management and optimization of energy usage and other critical parameters.
LoRaWAN industrial sensors empower manufacturers and chemical processing plants to:
Detect and eliminate waste before it drives up costs.
Transition from manual readings to automated insights.
Improve operational efficiency through data-driven decisions.
Achieve sustainability goals while maintaining profitability.
Retrofit Instead of Replace: Waltero’s LoRaWAN Gateways Solution
At Waltero, we understand that ripping out existing analog meters isn’t practical for most industrial businesses. That’s why we developed a retrofit LoRaWAN smart metering solution that converts any regular meter into a connected IoT meter without costly infrastructure upgrades.
With our W-Sensor retrofit solution, companies can:
Digitize existing meters in minutes.
Collect real-time energy usage data wirelessly.
Gain actionable insights through a cloud-based dashboard.
Set automated alerts for abnormal consumption patterns.
Implementing LoRaWAN Industrial Sensors
Implementing LoRaWAN industrial sensors involves several key steps to ensure seamless integration and optimal performance:
Installing the Sensors: LoRaWAN industrial sensors can be installed in various industrial settings, such as warehouses, factories, and other locations. Proper installation is crucial for accurate data collection and effective monitoring.
Configuring the Sensors: Once installed, the sensors must be configured to transmit data to a LoRaWAN gateway. This configuration ensures that the data is correctly forwarded to the LoRaWAN network server for further processing.
Setting Up the Network Server: The network server must be set up to collect, analyze, and store the data transmitted by the sensors. This setup is essential for centralizing data and making it accessible for analysis and decision-making.
Integrating with Other Systems: The data collected by the sensors can be integrated with other systems, such as energy management systems, location data systems, and data collection systems. This integration allows for a comprehensive approach to managing and optimizing industrial operations.
By following these steps, industrial organizations can effectively implement LoRaWAN industrial sensors, enabling them to collect and analyze data to improve their operations, reduce costs, and enhance overall efficiency.
3 Case Studies: Real-World Energy Savings with LoRaWAN Smart Meters
Case Study 1: Manufacturing Plant Saves 20% on HVAC Energy Costs
A large manufacturing facility deployed LoRaWAN sensors to monitor its HVAC energy usage. The data revealed that ventilation systems were running at full capacity even when production was idle. By optimizing operating schedules based on real-time insights, the company reduced HVAC energy costs by 20%—without affecting productivity.
Case Study 2: Compressed Air Leak Detection Saves Thousands
A metal processing plant installed LoRaWAN-connected energy meters on its compressed air system. Within days, the data showed significant power consumption spikes overnight, even when no production was happening. Engineers discovered a major air leak that had been draining thousands of dollars in wasted energy. Once repaired, the plant reduced its monthly energy costs by 15%.
Case Study 3: Water Pump Optimization in Chemical Processing
A chemical processing facility used LoRaWAN sensors to track energy usage across its water pumping stations. The sensors detected irregular consumption patterns, leading to the discovery of inefficient pump scheduling. By optimizing their usage, the plant saved 12% on electricity costs annually.
5 Financial and Operational Benefits of LoRaWAN Smart Metering
LoRaWAN smart metering offers utilities a leap into the future, enabling smarter and more efficient resource management.
1. Lower Energy Costs
By identifying inefficiencies and reducing unnecessary energy consumption, industrial plants can cut costs by 10–25%.
2. Fast ROI & Minimal Disruption
With LoRaWAN retrofit sensors, companies can upgrade to smart metering without expensive infrastructure changes—seeing a return on investment (ROI) in just months.
3. Improved Maintenance & Downtime Prevention
Continuous energy monitoring helps predict equipment failures before they happen, reducing costly unplanned downtime.
4. Accurate Data for Decision-Making
Industrial leaders gain real-time visibility into energy consumption trends, allowing for data-driven optimization.
5. Enhanced Sustainability & Compliance
Many industries face pressure to reduce carbon emissions and meet regulatory standards. LoRaWAN smart meters help track energy efficiency improvements, supporting ESG (Environmental, Social, and Governance) initiatives.
By embracing this advanced technology, utilities can unlock significant financial and operational gains while laying the groundwork for a more connected, data-driven infrastructure.
Conclusion
In terms of Waltero Industries, we believe that energy efficiency starts with better data. Without real-time visibility into consumption patterns, industrial companies risk wasting thousands of dollars every year on avoidable inefficiencies.
The best part? You don’t need to replace your existing meters to get started. With Waltero’s retrofit LoRaWAN smart metering solutions, you can unlock IoT energy savings today—without the hassle of costly upgrades.
Want to see LoRaWAN smart metering in action? Explore our Waltero Exploratory Kit to experience the power of real-time energy insights.
Anders Carlberg – Co-Founder & Director of Customer Success, Waltero
Anders is a hands-on entrepreneur committed to solving customer challenges through Waltero’s AI and monitoring solutions. With extensive experience in IT services, he guides utilities worldwide in adopting data-driven strategies for operational excellence.
