Unable to Recharge the prepaid meter

Solution: Connectivity Check: Confirm the meter is successfully communicating with the server. Serial Number Verification (SmartComm): Access the SmartComm Customer Master and ensure the serial number recorded matches the physical serial number of the connected meter. Duplicate Configuration Check: Verify that no two meters are incorrectly configured with the exact same serial number in the system.

Email Configuration SMTP Details Outlook

Solution: SMTP Host/Server Name: For Outlook.com: smtp-mail.outlook.com For Office 365/Microsoft 365: smtp.office365.com SMTP Port:587 (recommended) Encryption Method: STARTTLS Authentication: Your email account needs to be authenticated, so enable login or use the ""My outgoing server (SMTP) requires authentication"" option in your email client. Username: Your full Outlook email address (e.g., yourname@outlook.com or yourname@domain.com) Password: Blank

Email Configuration App Password creation for Gmail account

Reason - Gmail will work only with a secure encrypted app password Solution: Go to your Google Account settings. Navigate to the Security tab. If you don't have it enabled, turn on Two-Step Verification. Find and click on App passwords. Select an app name (like ""SMTP"" or ""Mail Client"") and click Generate. Copy the generated 16-character password and use it in your mail client's password field instead of your main Gmail password.

Email Configuration SMTP Details Gmail

Solution: Gmail SMTP Settings SMTP Server: smtp.gmail.com Port: 587: (requires STARTTLS/TLS) 465: (requires SSL) Authentication: Required Username: Your full Gmail address (e.g., user@gmail.com) Password: An App Password generated from your Google Account security settings Security/Connection: TLS or SSL, depending on the port chosen

Transfer existing sensor to a different gateway

Reason - Loss of old data stored under device id created Solution: To prevent data loss, edit the sensor and use the "Move to Gateway" option to transfer the sensor to a different gateway.

Asset list is not available in the filter

Reason - The asset is not assigned to the organization Solution: Check the asset selection settings in organization settings

Reason - Sensor/gateway limit exceeded Solution: Check license information for sensor/gateway limit

Cannot change the ip address of gateway

Reason - The ip address should is not available Solution: 1. if company network is being used check the accesibility to access 2. check if set ip is with in subnet range 3. Check if Primary and Secondary DNS is correct as per network settings 4. Set the Default Gateway IP to match the router's IP or the company network's default gateway IP.

3rd part meter not communication

Reason - 1. Memory map configuration wrong 2. (10 power -4 )Conversion factor is not available in third party memory map configuration 3. Data on modscan and software is matching but not matching with meter display readings Solution: 1. Verify data via Modscan, check wiring, confirm the meter parameter's datatype/function code in the memory map, and ensure the gateway supports that parameter datatype. 2. Can be added from conversion factor available in Master settings

Could not download certificate

Reason - All mandatory fields are not saved in organisation info settings Solution: All details should be given in mandatory field of organisation settings

Energy Management Solutions for Textile Industry

Updated: Sep 08, 2026 | 6 min read

Technical Articles

Published: Mar 11, 2026 by Divyesh B. Vaghasiya

Technical Articles

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Textile sector is considered as one of the largest industrial sector in India and at the same time it is also one of the oldest sectors in the country. In textile mills, electricity costs are increasing due to capacity additions and increase in tariff rates.

Analysis of per unit cost of production will reveal that electrical energy cost is around 15% - 20% of the production cost and is 2nd in terms of weightage in total product cost after raw material cost. Unlike other major cost components like raw material or labour, electricity consumed is an important leverage factor to reduce per unit production cost as the cost of others are based on market driven factors. A good Energy Management system installed in a plant will help to analyse energy consumption to take actions to reduce electricity consumption.

SmartComm Energy Management System will help in monitoring of energy consumption, give analysis of energy and hence help in taking actions to reduce energy usage thereby leading of cost reduction.

A CII study* on energy efficiency estimated that Indian textile Industry has the potential to save upto 20 to 30 percent of total energy consumption. Adjoining table indicates the average energy conservation potential in various energy intensive industries.

The textile mill can be majorly split into various processes based on the type of textile mills. Multifunction meters with communication port installed on the feeders of these process lines helps in monitoring their energy consumption.

Industry Energy Saving Potential

Iron & Steel	10%
Fertilizers	15%
Textiles	25%
Cement	15%
Chlor-alkali	15%
Pulp & Paper	25%
Aluminium	10%
Ferrous Foundry	20%
Petrochemicals	15%
Glass & Ceramics	20%
Refineries	10%

Iron & Steel	10%
Fertilizers	15%
Textiles	25%
Cement	15%
Chlor-alkali	15%
Pulp & Paper	25%
Aluminium	10%
Ferrous Foundry	20%
Petrochemicals	15%
Glass & Ceramics	20%
Refineries	10%

SmartComm EMS helps in real time energy monitoring and analysis with the mantra what gets measured gets acted upon.

Dashboard for a quick eye view of energy consumption with analytics.

Quick analysis

Textile plants have large usage of VFDs in plants that leads to harmonics on Electrical feeders. Hence ITHD and VTHD are important aspects to measure in textile plants. EMS Dashboard shows the % THD at feeder levels thereby helping in Power Quality Monitoring. SmartComm EMS can also help in monitoring individual harmonics upto 31st level with the help of advanced multifunction meter.

Penalties are imposed by the State Electricity boards when the plant crosses the contract demand allotted by EB. Max Demand Controller can help to avoid crossing of CD by means of 4 output relays to control the load. MD levels can be easily monitored at any point of time and can be reset from SmartComm EMS software on daily or monthly basis at a specified date.

UKG is an important benchmark for understanding the energy cost of production. It is referred to as energy consumed per unit of production. The user can upload the production data in SmartComm EMS and get details of UKG on shift basis, daily basis and monthly basis. This is also referred to as Specific Energy Consumption (SEC).

Payback calculations

Let us consider a medium sized textile mill for understanding purposes:

Total units / day: 1,30,000 units of electricity
Total production / day: 33000 kgs of yarn
Unit electricity rate: Rs.7.5 of electricity
Total cost /day (A *C) : Rs. 9.75 L
Energy Cost / kg i.e UKG (D/B): Rs.29.55
Total no of spindles: 70,000
No of Multifunction meters required: approx. 55-60 nos (assuming one machine with 1200 spindles)

Based on the above example -

Per spindle cost works out as Rs.7 L / 70000 spindles

= Rs.10 per spindle

Expense	Cost *
Cost of software	1.6 L
Protocol Convertors (RS485 to Ethernet)	0.7 L
Installation & Commissioning charges	1 L
Miscellaneous Charges	0.7 L
Multifunction meters (58 nos of 4410 series**)	3 L
Total	7 L

Expense	Cost *
Cost of software	1.6 L
Protocol Convertors (RS485 to Ethernet)	0.7 L
Installation & Commissioning charges	1 L
Miscellaneous Charges	0.7 L
Multifunction meters (58 nos of 4410 series**)	3 L
Total	7 L

Payback calculations

*This calculation is based on general site conditions and assumptions. Actual investment will be different based on site to site and meter required.

**Meters considered are 4410 series Class 1 with RS485 port in LED display with Basics, Power, Energy, THD%, ON hours, Events parameters.

Let us consider that with usage of EMS the user was able to identify and take corrective actions to avoid wastage of energy (some energy saving avenues are mentioned below) and let us assume this led to minimum 0.5% reduction in UKG from earlier levels.

H. New Energy cost/kg UKG (E * 0.995): Rs. 29.40

I. Difference (E - H): 0.15

J. Total difference in a month: (I X B X 30 days) = Rs.1.5L

Hence Payback works out to: 5 months approx. (Typically 5-8 months)

SmartComm EMS can help in identifying areas of electrical energy reduction and actions should be taken by the user to help reduce UKG.

Some of the Energy saving avenues that user can look into are:

Use of APFC (Automatic Power factor correction) system with capacitors in spinning.
Energy efficient motors for ring frame machines
VFD for supply air fan and on spray pumps of air handling section
Install variable speed drives for circulation pumps of dyeing machines
Seasonal control of fans pumps
Due to its nature of operations, the share of lighting in electricity use is relatively high which can be reduced
The textile industry that uses a vast number of relatively small electric motors may replace with motors of higher efficiency.

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About the Author

Divyesh B. Vaghasiya,

Senior Product Management and Marketing professional

Divyesh B. Vaghasiya is a Senior Product Management and Marketing professional focused on Industrial IoT, Energy Management, and Smart Technologies. With 13+ years of experience in the electrical and automation industry, he combines deep technical knowledge with strategic business thinking. He shares perspectives on emerging technologies, product management, sustainability, and digital transformation, helping businesses navigate the evolving energy landscape.