How the EEW Group Turned Energy Data into a Strategic Competitive Advantage
COMPANY
EEW Group
SECTOR
Steel Pipe Manufacturing
LOCATION
Germany · Korea · Malaysia
CUSTOMER SINCE
2015
~ €1 Mio
misinvestment prevented through data simulation
ISO 50001
certified energy management based on transparent data
200+ Mio
process data per day across all plants
5
facilities in Europe and Asia connected via a central network
Initial Situation
Data Silos, Manual Processes, and Increasing Certification Pressure
Before implementing acron, the EEW Group’s energy management relied on manual processes and Excel. ISO 50001 certification required a verifiable, data-driven energy management process—Excel could no longer meet that need.
The requirement was clear: software that the team could configure independently, based on open standards, and running in a uniform version worldwide—from Germany to Korea and Malaysia.
“We wanted software that we could configure on our own—without having to call on highly specialized support every time a change was needed,” said Markus Sonneborn, Energy Manager at the EEW Group.
Image: Welder | © Dan Petermann for EEW Group
Manual Data Collection via Excel
Prone to errors, time-consuming, and not scalable across multiple international locations
External Dependency
Every configuration change required external effort—that should be the exception, not the norm.
Self-Managed Site Data Management
Without a shared database, there can be no group-wide reporting or cross-functional key performance indicator management.
Compliance Virtually Impossible to Achieve
BAFA, customs, energy rebates (Germany) – all handled manually, without an audit-proof basis.
Solution
acron as the “Single Source of Truth”
From the machine level to the management dashboard—all data flows through a common architecture that functions identically at every location.
Level 1: acron – Data Collection & Analysis
Technical data is collected every three seconds. A centralized, tamper-proof database for analysis, reporting, and auditing.
Level 2: Power BI – Management Reporting
Data visualization for various user groups—usable by management, decision-makers, and subject matter experts with or without specialized knowledge, integrated into Microsoft Teams, accessible from any location worldwide.
Why the Choice Fell on acron:
Independence
Configurable without external support—the team has full control over setup and customization.
Open Interfaces
OPC UA via KepServerEX – freely combinable with ERP systems, PLC brands, weather data, CSV data, and more.
Global Consistency
Same version, same language, same standard—across all locations, from Germany to Malaysia.
Database Performance
No other system matches acron’s performance in data collection and archiving—even with very large amounts of data.
“The database is brilliant—nothing else comes close. The internal and external interfaces are top-notch. It’s exactly what we need, and it’s going to be a long-term solution.”
Markus Sonneborn, Energy Manager · EEW Group
Results & Added Value
What acron Has Changed within the Company
ECONOMICALLY
Data Basis for Investments
including the evaluation of PV proposals through simulation and in line with the electricity procurement strategy. Various concepts involving wind and PV plants were rejected due to insufficient data
→ A misinvestment was avoided.
Optimized Energy Procurement
Even during the energy price crisis, production continued without interruption. Thanks to strategic energy procurement, government subsidies were kept to a low five-figure amount.
→ Direct energy cost savings and reduced administrative burden associated with applying for subsidies.
OPERATIONALLY
One System for All Locations
Same version, same standards—from Germany to Korea. No media discontinuity, no room for interpretation.
→ Consistent across the entire group.
Status-Based Maintenance
Hydraulic oil, vibrations, temperature – maintenance only when necessary. Predictable repairs before breakdowns, less waste.
→ Higher plant availability. Lower costs.
COMPLIANCE & HSE
Regulatory Reporting without Extra Effort
BAFA, customs, emissions reports—all in a single, audit-proof database. No manual compilation required.
→ Legal certainty during audits.
Audit-ready HSE Documentation
Noise, particulate matter, CO₂ – customized long-term measurements conducted directly on-site, without third-party service providers and without extrapolation.
→ Real data with no room for interpretation. Lower costs for external consultants and internal knowledge-building (lessons learned) for future projects.
Areas of Application
From Energy Management to Data Platform
“It’s not as if acron is fully utilized yet – just when you think you’ve seen it all, you discover a new area of application that’s interesting.” — Markus Sonneborn, Energy Manager · EEW Group
ENERGY MANAGEMENT
ISO 50001 · Measurement data collection · KPI calculations
STRATEGIC ENERGY PROCUREMENT
Day-Ahead market data · Load profile analysis · Simulation
REGULATORY REPORTING
Main customs office · BAFA · BEHG · Leakage regulation
CARBON FOOTPRINT
Corporate CCF and Product PCF
HSE & QUALITY
Noise · Particulate Matter · CO₂ · Humidity
CONDITION MONITORING
Hydraulic oil · Vibrations · Oil temperature
CAPEX DECISIONS
PV simulation · Wind power · Solar storage
KEY PERFORMANCE INDICATOR MANAGEMENT
Group-wide KPI system – standardized globally
OCCUPATIONAL SAFETY
Noise inventory · Fine particle pollution in the workplace
Case Study
When Numbers Say It All – and Investments Become Clear
Time and again, suppliers approached the EEW Group with PV proposals. Instead of relying on glossy brochures, the team put the numbers from acron on the table: historical load profile data, simulated PV yields, feed-in tariffs, grid fees, and electricity price trends.
The result was the same every time—the systems weren’t cost-effective. All it took was a few hours of analysis.
A simulation for the integration of solar storage systems is currently underway using the same data set.
~ €1 Million In Misinvestments
have been avoided over the years—thanks to data, not gut feelings.
Image: PV Graph | © EEW Group
“When it comes to measurement data, there is currently no software on the market that could replace acron.”
Markus Sonneborn, Energy Manager · EEW Group
Looking ahead
An Eye Toward the Future
AIP: Predictive Maintenance
In the future, error messages from the PLC will be assigned directly to the responsible maintenance technician—currently in the pilot phase..
Solar Storage Simulation
Since the PV simulations have shown that the project is not financially viable, a simulation of solar storage integration is now running in parallel with the real-time load profile—using the same data set in acron.
Power BI as a Global Reporting Layer
While data visualization can be further customized, acron remains the data foundation. Data becomes accessible to various user groups—from management to technical staff—and meets their specific needs across locations worldwide.
Image: Logistics | © EEW Group
Customer Profile
EEW Group
The EEW Group is a leading global manufacturer of large-diameter steel pipes for offshore wind energy, pipelines, and infrastructure projects. With production facilities in Germany, Korea, and Malaysia, the Group operates under strict standards for quality, efficiency, and international scalability.
Energy management is coordinated centrally by EEW Management Service and linked to the individual plants. Since 2015, acron has been the technological backbone of this system.