## 4 Outcome
### Detecting and Resolving Air Leaks  
Access to collected data and their visualization is essential for identifying operational inefficiencies and detecting hidden issues. A comparison of air and energy consumption graphs (Figures 15 and 16) revealed an unexpected anomaly, suggesting a potential air leak. On one day, despite the machine being in standby mode with low energy consumption (midnight to 5 p.m.), air consumption remained unusually high, exceeding 7 m\({}^{3}\)/h. This discrepancy raised immediate concerns, prompting further investigation into its cause and impact on efficiency.  
Figure 16: Air consumption of Wiedemann machine on 22 April 2024.  
It was noted on September 16 th that, even when the machine was completely powered off between 4 a.m. and 5 p.m. (Figures 17 and 18), air consumption remained consistently high at 4-6 m\({}^{3}\)/h, indicating a persistent air leak. This ongoing leakage increased the load on the factory's air compressors, which supply compressed air for production. Consequently, the compressors had to operate at a higher capacity, leading to increased power consumption and rising operational costs.  
Figure 17: Electricity consumption of Wiedemann machine on 16 September 2024.  
Figure 18: Air consumption of Wiedemann machine on 16 September 2024.  
To address this issue and enhance energy efficiency, a customized solution was developed. The sensor was reconfigured to generate an output signal when the machine's instantaneous power consumption dropped below 1 kW. This signal was integrated into the system to automatically trigger the shut-off valve, stopping air flow during non-operational periods.  
The effectiveness of this modification is clearly demonstrated in the comparison plots (Figures 20 and 21), where the system successfully eliminated air leaks. By preventing unnecessary air loss, the solution not only conserved compressed air, but also reduced the workload on air compressors, leading to significant energy savings and cost reductions.  
A detailed comparison of monthly air consumption before and after the implementation of the shut-off valve (Figure 22 and Table 2) highlights its substantial impact. Prior to the modification, from the installation of the MP-F series sensor in February 2024 until the shut-off valve was set up, the machine's monthly air consumption consistently exceeded 2500 m\({}^{3}\). The lowest recorded consumption during this period was 3181.41 m\({}^{3}\) in May 2024,  
Figure 19: Keyence shut-off valve operation based on air flow.  
Figure 20: Day 1 (16 September 2024): air leak of \(\sim\)5 m\({}^{3}\)/h detected when the machine is off (12:00–5:00 a.m., 5:00 p.m.–12:00 a.m.).  
while the highest reached 6336.03 m\({}^{3}\) in September 2024, with an average consumption of 4055.51 m\({}^{3}\) per month. A significant portion of this air usage resulted from leaks, which peaked in September 2024.  
Following the implementation of the shut-off valve, air consumption dropped dramatically, averaging 675.54 m\({}^{3}\) per month over the next three months. This represents an impressive 83.34% reduction in air consumption. Such a substantial decrease has a profound impact on the factory's main compressors, as it significantly reduces their load. Since these compressors are responsible for maintaining the required air pressure across the facility, reducing their workload translates into lower power consumption, extended equipment lifespan, and decreased maintenance costs. Ultimately, this improvement not only optimizes energy efficiency, but also enhances the overall sustainability of the factory's operations.  
Figure 21: Day 2 (18 September 2024): air leak fully stopped with a smart shut-off valve.  
Figure 22: Machine’s monthly air consumption in year 2024.