How connected technologies are reshaping industrial energy use in 2025
As energy costs rise and sustainability targets tighten, manufacturers are turning to the Industrial Internet of Things (IIoT) to transform how energy is monitored, managed, and optimised.
Here are the top five IoT innovations revolutionising energy efficiency in manufacturing today.
- Smart Sensors and Real-Time Monitoring
At the heart of every IIoT system are smart sensors. These devices continuously track energy usage across machinery, lighting, HVAC systems, and even specific production lines. By providing granular, real-time data, smart sensors reveal inefficiencies and help teams take immediate corrective action. This visibility replaces guesswork with precision, enabling data-driven decision-making.
- Predictive Maintenance
Unplanned downtime is one of the most energy-inefficient scenarios in any factory. Predictive maintenance uses IoT sensors to monitor equipment performance indicators like vibration, temperature, and electrical load. When anomalies are detected, alerts are triggered before breakdowns occur. This reduces energy waste from malfunctioning equipment, extends asset lifespan, and ensures operations remain smooth and efficient.
- Edge Computing and AI Integration
Edge computing enables data to be processed at the source rather than in the cloud. When paired with AI, this creates ‘Edge AI’ systems that respond instantly to performance changes. These systems can automatically optimise energy usage, reroute power, or shut down idle equipment without human intervention. The result is faster decision-making, reduced latency, and improved cybersecurity, since sensitive data stays within the facility.
- Wireless Connectivity for Scalable Insights
Wired networks offer speed and reliability, but wireless IIoT solutions are growing in popularity for their flexibility. These connections allow manufacturers to quickly scale energy monitoring across multiple buildings, assets, and even sites, without the expense or disruption of additional cabling. This ease of deployment accelerates energy optimisation efforts.
- Automated Energy Management Platforms
Cloud-based energy management platforms integrate data from sensors and meters across entire operations. They visualise energy trends, identify cost-saving opportunities, and enable automated controls. From adjusting machine loads during peak hours to optimising compressor sequences, these platforms act as a central hub for turning raw data into actionable efficiency.
By embracing IIoT, manufacturers can cut energy costs, reduce carbon emissions, and future-proof their operations. In 2025, the smartest factories aren’t just automated—they’re intelligent, connected, and energy-optimised.
