The Client
Slape and Sons has been a proud, family-owned food manufacturer in South Australia since 1965, known for their handcrafted sausages, burgers, and rissoles. With decades of steady growth, the Newton-based business has stayed true to its traditional values while evolving into a nationally recognised brand.
In 2024, they took a major step forward, relocating to a purpose-built facility designed to support long-term sustainability and innovation. This wasn’t just about expanding capacity; it was about working smarter.
Partnering with IoTics, Slape and Sons implemented an advanced energy management system that gives them real-time control over power use across the site; reducing costs, improving resilience, and future-proofing their operations.
Challenge
Slape and Sons, a family-owned meat processing company in South Australia, embarked on a major relocation and upgrade in 2024. With their facility expanding for a third time since 1965, they needed to meet new building code compliance requirements tied to government grants; specifically, the inclusion of an integrated energy management system.
Beyond compliance, they faced multiple operational hurdles:
- The site’s rated power supply was lower than the projected consumption, especially from their innovative thermal battery refrigeration system; a first of its kind in Australia
- The site-based backup generator (500KVA) was undersized for full plant operation.
- Rising energy costs and volatile tariffs posed financial risks, prompting the need for a load management solution that could respond in real time to energy spot pricing.
Solution
IoTics delivered a smart, flexible energy management and automation system that could adapt as Slape and Sons’ needs evolved. The solution allowed their entire facility to work together seamlessly from the refrigeration plant to lighting and solar.
Key parts of the system included:
- A central control unit that acts as the brain of the facility, connecting all major equipment and energy systems.
- Energy monitoring devices installed across the site’s power boards, making it easy to track where and how power is being used
- Seamless communication between different machines and systems, regardless of brand—allowing everything from refrigeration to solar panels and backup generators to coordinate in real time.
- Integration with live electricity pricing data from the Australian Energy Market Operator, enabling the system to automatically adjust energy use based on current market rates.
The system dynamically controls refrigeration, microwave, and mincer machines, shifting them into various power modes based on:
- Peak demand thresholds
- Live spot price data (including negative pricing scenarios)
- Generator availability during outages
A web-based Simatic PC Station and Siemens Energy Manager Pro dashboards were installed to provide operators with real-time visibility, live KPI tracking, carbon emissions data, and monthly reporting.
Outcome
- Energy Cost Reduction: Automated scheduling and real-time spot price responsiveness have created significant opportunities for savings.
- Peak Demand Management: Prioritised load control avoids main breaker trips and optimises generator usage.
- Compliance Achieved: Full alignment with new energy regulations made Slape and Sons eligible for substantial government grants.
- Operational Visibility: Dashboards and monthly reporting deliver transparency and actionable insights.
- Future-Ready Design: Easily expandable architecture and vendor-agnostic integration ensure longevity and adaptability.
This project showcases the power of intelligent energy automation to support sustainability, cost control, and operational reliability, laying a scalable foundation for Slape and Sons’ future growth in the Australian food manufacturing sector.
