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Nissha Metallizing Solutions: Energy Forecasting & Contract vs Spot Price Optimisation

Facing volatile energy markets, Nissha partnered with Faktion to deploy an AI-powered forecasting tool, enabling precise energy predictions, optimised contract decisions, and enhanced sustainability performance.

Nissha Metallizing Solutions is a global leader in coating and metallising processes, which involves energy-intensive manufacturing processes. To align with its sustainability goals and cost optimisation strategies, Nissha has integrated renewable energy sources like wind and solar power into its energy mix.

Given the unpredictable energy prices in the spot market and potential prices increases, Nissha aims to predict accurately its energy needs and negotiate energy contracts upfront with a predetermined price.

To achieve this, Nissha needed a unified energy system that:

  • Has detailed data of production plans for the next periods
  • Understands complex and energy-intensive production process
  • Can accurately predict the amount of wind and solar energy produced.

Hence, this system can accurately predict Nissha's energy needs in the future.

Navigating energy contract negotiations has been incredibly challenging due to the volatility of energy prices and the fragmented nature of our data sources.
Dirk Bijnens
Site Manager
of
Nissha Metallizing Solutions NV

Need

Precisely predicting manufacturing energy consumption and renewable energy production to optimise energy contracts and reduce dependency on fluctuating spot prices.

The solution

Energy Forecasting & Optimisation System

Faktion partnered with Nissha to design a robust tool that consolidates energy data, forecasts production and consumption, and simulates future scenarios for contract optimisation.

Integrated Data Dashboard

Consolidates manufacturing schedules, historical energy consumption, renewable energy production, and spot energy prices. The tool also tracks trends in energy demand, production, and prices to support data-driven decision-making.

Advanced Visualisations

Tracks trends in energy demand, production, and prices to support data-driven decision-making.

Advanced Forecasting & Simulation

Enables users to simulate alternative futures, such as high or low renewable production or unfavourable energy prices. Outputs include: Predicted total energy demand and grid consumption, renewable energy production, and spot price trends.

Contract Cost Comparison

Evaluates energy contracts based on pledges and pricing, compare scenario-based cost estimates while incorporating fixed renewable energy costs for realistic calculations.

Integrated Data Dashboard

Consolidates manufacturing schedules, historical energy consumption, renewable energy production, and spot energy prices. The tool also tracks trends in energy demand, production, and prices to support data-driven decision-making.

Advanced Forecasting & Simulation

Enables users to simulate alternative futures, such as high or low renewable production or unfavourable energy prices. Outputs include: Predicted total energy demand and grid consumption, renewable energy production, and spot price trends.

Contract Cost Comparison

Evaluates energy contracts based on pledges and pricing, compare scenario-based cost estimates while incorporating fixed renewable energy costs for realistic calculations.

Approach

Faktion’s approach focused on iterative development and close collaboration with Nissha to deliver a tailored solution:

  1. Data Integration and Exploration:
    • Consolidating diverse datasets (e.g., renewable production, spot prices, and manufacturing plans).
    • Validating inputs with domain experts to ensure accuracy and relevance.
  2. Predictive Modelling and Simulation:
    • Developing machine learning models to forecast energy consumption and renewable production for various scenarios.
    • Simulating alternative futures, allowing NMS to assess risks and optimise contract strategies.
  3. Tool Development:
    • Building a modular and intuitive tool with functionalities to:
      • Upload and visualise input data.
      • Tweak parameters like renewable usage costs, pledge levels, and spot prices.
      • Generate visualised contract cost comparisons.
  4. Deployment and Iteration:
    • Delivering the tool in phases, allowing user feedback and iterative refinement.
    • Ensuring compatibility with Nissha’s IT ecosystem and compliance with sustainability goals.

Outcome

Successfully navigating complex energy management & cost

The AI-powered energy forecasting & optimisation tool transformed how Nissha manages energy procurement, pricing, and consumption.

  • Real-time insights into energy demand, consumption and production.
  • Smarter energy contract selection, reducing exposure to spot prices.
  • Reduced manual workload due to automated forecasting and planning.
  • Much more sustainable energy management.

By adopting this innovative solution, Nissha now has the tools to navigate energy market volatility, maximise renewable energy utilisation, and achieve cost-effective, sustainable operations.