Project Overview
Tata Motors required an intelligent and scalable system to measure, monitor, and optimize water consumption across its plants. By leveraging UniConverge Technologies LoRaWAN-based IoT infrastructure, they now benefit from real-time monitoring, rapid leak detection, and significant operational savings.
How It Works
Smart Flow Meters
Measure water usage continuously with ultrasonic or inline sensors
LoRaWAN Gateways
Transmit encrypted readings over long-range networks
Cloud Server
Securely stores and processes usage, alerts, and insights
Real-time Dashboard
View, analyze, and manage from anywhere via mobile or desktop
LoRaWAN Sensor Deployment at Tata Motors
To successfully digitize water usage tracking across Tata Motors’ extensive manufacturing infrastructure, UniConverge followed a structured 3-stage deployment approach customized to on-ground realities:
Stage 1: Integration with Existing Infrastructure
Several mechanical and electromagnetic flow meters were already in use. LoRaWAN-compatible converters (Pulse to LoRa, RS485 to LoRa) were deployed to extract real-time readings. Plug-and-play sensor nodes were added where needed.
- ✔️ Quick wins without major hardware changes
- ✔️ Unified data stream from mixed meter types
Stage 2: Contactless Metering Deployment
Clamp-on ultrasonic meters and Energy Tags were deployed in compact or overhead zones. These contactless devices were paired with LoRaWAN converters and operated battery-free for up to 10 years.
- ✔️ Non-intrusive, rapid installation
- ✔️ Accurate monitoring in hard-to-access areas
Stage 3: Inline Meter Installation
For high-flow areas, inline electromagnetic meters were installed directly onto pipelines. These sensors provided robust, industrial-grade precision even in challenging factory environments.
- ✔️ Enterprise-grade accuracy
- ✔️ Full-spectrum water tracking from source to drain
Key Results
30%
Reduction in water usage
95%
Faster leak detection response time
₹2.5 Cr
Annual savings
Scalability & Future Roadmap
- Rollout across 8+ Tata Motors manufacturing plants
- Include monitoring for electricity, gas, and air flow
- Deploy AI-based predictive maintenance analytics
- Launch “Water-as-a-Service” platform for external factories
Bring Smart Water Management to Your Facility
Talk to UniConverge to explore scalable LoRaWAN-based water metering solutions tailored for industrial applications.
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