PAUL RAUSCHERT STEINBACH GMBH has implemented Mitsubishi Electric’s GENESIS energy management platform, transforming monthly compilation of 20-page Excel spreadsheets into real-time energy insights and reducing peak consumption analysis from hours to minutes.
A clear vision
Paul Rauschert Steinbach GmbH has enjoyed 120 years of success as a manufacturer of technical ceramics for precision components, ignition systems, heating elements and plastic moulded parts, thanks to decades of experience and expertise. However, urgent action was required in energy management. The outdated systems provided isolated data from several buildings without clear visualisation and were no longer supported.
Winter energy consumption peaks occurred without explanation, while monthly energy reports required extensive manual compilation —a time-consuming process that delivered information too late for effective intervention. EU mandatory energy reporting requirements further intensified the administrative burden, demanding significant manual effort from dedicated personnel.
“We had data, but no understanding,” explains Fabian Völk from Rauschert’s Maintenance/Construction Plant Engineering team. “When energy peaks occurred, we couldn’t trace their origin. Our monthly reports required extensive manual compilation – a time-consuming process that delivered information too late to be useful.”
When legacy meets data intelligence
Mitsubishi Electric’s GENESIS platform was implemented to address these visibility gaps and transform Rauschert’s approach to energy monitoring. The Energy Management tools within GENESIS connect with existing energy meters while storing historical energy data for analysis and reporting.
These tools deliver open universal data connectivity and enterprise integration with existing control systems. Built-in capabilities include calculations, KPIs, analytics, Data Historian, and reporting. Compatibility with multiple meter types enables quick deployment and faster return on investment through reduced engineering time.
The system enables real-time energy monitoring across all facility buildings with immediate identification of consumption peaks. When winter energy spikes occur, operators can trace their source through intuitive power distribution diagrams — from facility level down to specific equipment or building sections. Asset-based management allows users to drill down to specific sources of energy inefficiencies and locate suspected consumption offenders.
Automated report generation replaces manual compilation processes. EU compliance reporting now requires single-click data extraction. Standard reports include consumption, cost, and carbon data for electricity, gas, water, and other utilities alongside operational conditions. The expandable architecture accommodates future facility growth with custom visualization tailored to Rauschert’s operational needs.
From hours to minutes
The implementation transformed Rauschert’s energy management from monthly manual compilation to one complex view of consumption, delivering actionable insights immediately. Energy peak investigations that once required hours of manual data analysis now take minutes through visual consumption mapping and drill-down capabilities that pinpoint specific consumption offenders.
“The difference is clear,” notes Fabian Völk from Rauschert’s engineering team. “We’ve eliminated the time-consuming manual processes that once dominated our energy reporting. What used to require dedicated personnel compiling data across multiple systems now provides instant analysis and useful insights for energy optimization. Our EU compliance reporting, once requiring extensive manual work, now requires a single click.”
The implementation demonstrates how established facilities can successfully adopt modern energy monitoring solutions without disrupting proven production processes. Quick deployment capabilities enabled faster ROI through reduced engineering time and integration with existing infrastructure.
“What made the difference at Rauschert was giving facility personnel clear visibility into their energy data. This transparency enabled them to quickly identify optimization areas and find ways to maintain production efficiency while reducing consumption across their infrastructure,” notes Christian Nomine, European Strategic Product Manager Visualisation & Analytics at Mitsubishi Electric Europe B.V.
BOX: Energy efficiency as a global lever
According to the latest report by the International Energy Agency (IEA), industry accounts for around 39% of global final energy consumption, so the challenge extends beyond individual plants. In energy-intensive industries, energy costs can account for up to 30% of operating expenses.
Systematic energy management typically leads to energy savings of more than 10% within the first three years. Many companies achieve even greater savings, especially when energy-efficient technologies are used alongside operational improvements. In individual cases, reductions of up to 60% are possible with long-term commitment.
The global savings potential is enormous: aligning with the most energy-efficient companies in IEA member countries alone could save up to £600 billion per year. According to the IEA, investments in energy management and efficiency measures usually pay for themselves within three years.
Sources:
(Quelle: IEA, Energy Management for Industry, 2025) www.rinnovabili.it/wp-content/uploads/2025/09/IEA-Energy-Management-for-Industry.pdf
Further Information Genesis: Smart Manufacturing Solution: GENESIS Version 11
