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Industrial Automation Systems for Indian Factories
Your Facility.
Fully Automated.
Factory floor controls, motor management, safety monitoring and energy optimization for industrial facilities across India.
✓ Designed in India✓ Works Offline✓ Encrypted in Transit✓ Reply in One Working Day
Nexomatic · Industrial
MOTORS
6/8
SAFETY
OK
POWER
42kW
TEMP
31°C
ENERGY TODAY · 280kWh
All Devices · 64/72
What We Automate
Every System in Your
Facility — Connected
From the factory floor to the control room — we automate everything for safety, efficiency and uptime.
Factory Floor Lights
Zone-based
Motor Controls
Start · Stop
Safety Sensors
Smoke · Gas
Gate & Entry
Motorised + video
CCTV
Live + recording
Energy Monitoring
Per machine
Power Factor
Per machine · penalty check
Exhaust Systems
Auto-ventilation
Water Pumps
Level-based
Perimeter Beams
Up to 100 m
Data Export
Feeds your ERP
Why Automate
Operations Get Better When
Your Facility is Smart
Industrial automation reduces downtime, improves safety compliance and optimizes energy usage at scale.
Reduce downtime significantly
Predictive monitoring and automated alerts catch issues before they become failures.
Safety compliance at all times
Automated safety sensors, emergency shutoffs and access control meet all industrial standards.
Power-factor penalties found and removed
Every machine's voltage, current, power and power factor every 30 seconds, read against your electricity bill. At MJK Enterprises, a Coimbatore cold store, this turned a ₹2,754 penalty per bill (13% of the bill) into zero, lifted power factor from 0.65 to 0.95, and cut a loaded freezer’s energy by 55%.
Energy optimization at scale
Per-machine energy monitoring identifies waste and optimizes motor run times automatically.
Remote facility monitoring
Monitor your factory from anywhere — motor status, safety alerts, energy usage all on your phone.
The data leaves the app
Per-machine consumption, run hours and alarm history are available to your own systems, so energy sits in the same place as the rest of your production reporting instead of in a separate dashboard nobody opens.
0.65 → 0.95
Power Factor, Cold Store
5 Days
Installation Time
₹0
PF Penalty After Fix
1 day
Reply Time
Power factor & power consumption · case study
From a growing electricity penalty to zero
M/s MJK Enterprises, an ice-cream cold store in Coimbatore with five deep freezers, found a new line on its two-month bill: “Penalty for LPF”, ₹2,753.65, 13% of the bill — in a cycle where it had used 26% less electricity. We metered every freezer for a month, found the cause, and recommended a ₹12,500 fix. The freezers now run at a power factor of 0.90–0.98, up from 0.65.
₹2,754 → ₹0
PF penalty, 13% of the bill
0.65 → 0.95
Freezer power factor, average of 5
55% less
Energy, a loaded freezer
4–14 bills
Payback on ₹30,000
What the meters showed
- The freezers were the penalty. About 56% of the site’s energy but 73% of its reactive power, at a power factor of 0.65.
- No freezer was faulty. Uncorrected compressor motors behave this way. The fix was correction, not replacement.
- High mains voltage made it worse. Nights reached 255–270 V, above the 254 V supply limit for 22% of the month; the higher the voltage, the lower the power factor.
- And it was getting worse. By October the meter read 0.68 — a penalty of ₹4,561 on every bill, ₹27,366 a year.
- Power consumption fell by more than half. A loaded freezer used 7.43 kWh a day in August and 3.38 kWh a day in October — 55% less — with our duty control, its correction capacitor and a stabiliser in place.
- Scheduling would not fix the power factor. Fewer, longer or staggered runs barely moved power factor — so we said so.
Power factor per freezer, before and after
Freezer 1
0.66
0.98
Freezer 2
0.63
0.90
Freezer 3
0.65
0.97
Freezer 4
0.65
0.96
Freezer 5
0.66
0.92
August, beforeOctober, after correction 0.85: below this the utility charges a penalty
29% less current for the same compressor (2.06 A down to 1.47 A at 232 V). With a stabiliser, 18% less power on high-voltage nights (320 W at 227 V against 380–406 W unstabilised at 255 V).
How the penalty is calculated in Tamil Nadu
Three-phase LT III-B services must keep an average power factor of 0.85 or above (TNERC order, June 2025).
- 0.85 and above
- No penalty
- 0.75 to 0.85
- 1% of consumption charges for every 0.01 below 0.85
- Below 0.75
- 1.5% for every 0.01 below 0.85 — the whole shortfall at the higher rate
So 0.75 is a cliff: at 0.76 the penalty is 9% of consumption charges, at 0.74 it is 16.5%. This site’s bill read 0.747.
How we work
- 1
Monitor
A metering switch on every machine: voltage, current, power and run time every 30 seconds, live in the app.
- 2
Report
Energy and power-factor reports read against your own electricity bill, machine by machine.
- 3
Recommend
Right-sized correction per machine, stabilisers where the supply runs high, and what not to spend on.
- 4
Prove
The same meters measure the result, so the saving is shown, not promised.
Investment on this site: ₹12,500 correction capacitors, ₹17,500 metering and control for five freezers, and a ₹250-a-month monitoring subscription. The capacitors alone paid for themselves in 2–5 bills.
Paying a power-factor penalty, or not sure where your units go? Send us your last two electricity bills and we will tell you what metering would show — before you buy anything.
Get your bill checkedPower factor here is true power factor (real power ÷ voltage × current) from 30-second readings. Before: 19 days, August 2026. After: October 2026. Penalty figures use the site’s August 2026 bill (₹21,265, penalty ₹2,753.65). Energy: the same freezer’s meter, 10–14 August against 17–26 October 2026, integrated from power readings.
Use Cases
Automation Scenarios
Built for Indian Industrials
Production
Production Start Mode
At shift start — factory lights on, motors enabled, ventilation activated, safety systems armed.
Safety
Safety Alert Mode
On hazard detection — emergency lights on, motors stopped, alarms activated, exits illuminated.
Maintenance
Maintenance Mode
Selected zone powered down, lockout engaged, maintenance crew notified, safety barriers activated.
Perimeter
Boundary Crossed
A dual-beam detector on the compound wall trips: yard lights come on, the gate closes, cameras start recording and the alert reaches the phone — while the intruder is still outside the building.
Night
Night Security Mode
All production off, security cameras to high alert, perimeter sensors active, guard patrol tracking on.
Compatible Products
Products Used in
Industrial Automation
How It Works
From Consultation to
Full Automation
1
Free Site Assessment
Our industrial team surveys your facility, maps every zone and recommends the right devices and configuration.
2
Custom Design
We design a zone-based automation layout with safety protocols, energy targets and shift-based scheduling.
3
Phased Installation
Our technicians install zone by zone during non-production hours. Typically 3–7 days.
4
Operator Training & Go-Live
We train your operators, configure all safety protocols and connect you to industrial support.
FAQ
Industrial Automation
Questions Answered
Nexomatic switches handle standard loads up to 10A per channel. For high-voltage motors, we use contactors controlled by our smart switches — safe and compliant.
Can't find what you're looking for? Contact our customer support team →
Related reading
Automation for other spaces
Ready to Automate Your Facility?
Let's Make Your Facility
Truly Smart Today
Free site assessment · Qualified electrician install · Phased setup · Reply within one working day. Tamil Nadu and Growing.