Mergon International Initial Lumina+ Deployment

Mergon Group's manufacturing facility in Castlepollard operates across two plants and had accumulated around 30 energy meters as part of a legacy monitoring system. When the system provider was discontinued, Mergon were left with functional hardware but no way of communicating with it and no platform for energy management. Replacing the meters was one option. Lumina offered a better one: deploy a LoRaWAN wireless network across both plants and integrate all existing meters directly, eliminating the cost and disruption of rewiring. Historical data was migrated to the Lumina+ platform, giving the operations team continuity of data alongside live monitoring from day one.

With the platform in place, Lumina began designing targeted solutions for specific operational requirements as they emerged. Additional LoRaWAN current sensors were added to extend coverage to machine and sub-board level. Temperature sensors were deployed on chiller flow and return circuits. An ultrasonic flow meter was installed on one of the chillers without any disruption to operations, along with pulse counters to monitor water and process flows across the facility. Temperature and humidity sensors were added on two machines. Total site electricity consumption is monitored via the two main panel meters across both plants, cross-checked to within 1% of the utility bills.

Six wireless vibration sensors were subsequently added as a proof of concept for predictive maintenance on key rotating machinery, with ML algorithms developed to detect changes in equipment behaviour over time. The programme at Castlepollard demonstrates how Lumina works as a long-term operational partner: the initial deployment solves the immediate problem at best value, and the platform grows with the operation as new monitoring requirements surface.