How Mars Eliminated Hidden Energy Waste and Achieved 7x ROI with Real-Time Monitoring
Client
Industry:
Food & Beverage
Machines
Connected:
Reading time:
~3 minutes
Steam systems are one of the biggest hidden cost drivers in manufacturing.
At Mars, critical steam infrastructure was operating without real-time visibility—meaning failures were happening silently, impacting energy costs, uptime, and sustainability.
Like many plants, they had data… But not the kind that drives action.
For maintenance teams, steam traps are critical, but notoriously difficult to manage.
Mars faced the same challenges most manufacturers deal with:
The result?
Energy loss, unnecessary costs, and constant firefighting.
Maintenance teams stretched thin with manual rounds
Boilers compensating for lost steam → higher energy spend
No prioritization, everything looked equally urgent
Teams reacting to problems instead of preventing them
In reality: Time was being spent everywhere… but impact was limited.
Mars transformed their approach with Shoplogix Steam Trap Monitoring (STM). Why it worked for maintenance teams:
Every trap is monitored in real time, no blind spots
Teams respond to actual failures, not assumptions
No more unnecessary inspection rounds
Self-powered sensors remove ongoing maintenance tasks
Clear view of system health across the plant
This wasn’t just monitoring. It was operational clarity at scale.
within 3 months
payback period
steam trap failures identified early
system visibility achieved
metric tons of CO₂ reduced annually
Most importantly: Maintenance teams shifted from reactive to proactive.
Annual inspections are no longer enough in modern operations
Hidden utility losses can quietly erode margins
Real-time data empowers faster, smarter decisions
Eliminating low-value tasks frees teams for high-impact work
If your team is still relying on periodic checks, you’re likely:
Shoplogix helps you uncover and act on hidden losses, without adding complexity to your operations.
This is more than a steam trap solution.
It’s a step toward a fully connected, data-driven operation, where every decision is backed by real-time insight. ctory of the future, where every shift, every line, and every team operates with clarity and confidence.
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