Complete IoT & Energy Monitoring Solution

Lumina designed and deployed an IoT monitoring solution for Mergon Group's manufacturing facility in South Carolina, covering electrical metering, vibration analysis, and process monitoring across the full facility.

A LoRaWAN wireless network with three gateways provides full site coverage without disrupting production. Electrical metering covers 33 assets: blow moulding machines, injection moulding machines, chillers, compressors, and dust collectors, using a combination of 40 current sensors across single and three-phase circuits. Six ultrasonic flow meters, twelve temperature sensors, and six pulse counters monitor the process circuits.

Six wireless vibration sensors were deployed on key rotational machines as a proof of concept, with anomaly detection algorithms developed to detect deviation from normal operating signatures. Across all monitored parameters, the system generates real-time email alerts when values go out of bounds, keeping the operations and maintenance team informed without needing to check dashboards manually.

The Lumina+ platform is fully embedded in the team's daily operations. Mergon extracts data directly from Lumina+ via the open REST API, merging it with their internal production systems.