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ManufacturingEnergy monitoringMarketIQ

How Gates achieved $240,000 in first-year savings through energy monitoring

Stratford, OntarioIESO
Energy monitoring case study
$240,000
in first-year savings through energy monitoring
12.3%
reduction in electricity use
$240,000
in first-year savings
150%
ROI
The Challenge

During the economic downturn, Gates reduced operations to a five-day production week. However, part of the furnace system continued to idle at full temperature over the weekend because restarting it was difficult and operationally sensitive. Management wanted to know whether the savings from full shutdown would outweigh the restart burden, but lacked the data needed to evaluate the question properly.

The broader issue was that Gates had no clear way to understand gas use by production area in real time. Monthly utility bills did not provide enough detail to support operational decisions.

Our Solution

Union Gas initiated an EM&T research project and engaged Energent as the delivery partner. The platform provided real-time feedback and predictive modeling that allowed Gates to connect energy performance directly to operational behavior.

This gave plant management a much more practical decision-making framework, helping the team evaluate specific operating changes and measure their effect on energy intensity and cost.

Implementation
  • Union Gas initiated an EM&T research project and engaged Energent as the delivery partner. The platform provided real-time feedback and predictive modeling that allowed Gates to connect energy performance directly to operational behavior. This gave plant management a much more practical decision-making framework, helping the team evaluate specific operating changes and measure their effect on energy intensity and cost.
  • With real-time monitoring and predictive capability in place, Gates was able to evaluate operating decisions more accurately and identify where process changes were creating measurable savings. The project demonstrated how energy information tools could support both day-to-day decision-making and longer-term performance improvement.
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ManufacturingMarketIQ

How Rodan identified $170,000 in gas savings for a food manufacturer

Energy analytics case study - food manufacturing
13,000,000
SCF of gas savings identified
$130,000
estimated savings during one period
400,000
SCF additional savings identified
$40,000
further savings with a 2.5-month payback
The Challenge

The manufacturer needed to understand whether biogas could be incorporated cost-effectively into its operation. At the same time, the organization wanted to identify hidden operational savings and understand how process changes were affecting fuel consumption.

Without a strong analytical framework, it would have been difficult to separate normal usage fluctuations from true savings events or compare test periods against a reliable target baseline.

Our Solution

Rodan used its energy management platform and energy analyst support to compare actual gas use against a modeled baseline and interpret results through CUSUM analysis. This allowed the client to evaluate specific operating periods, understand where consumption was below target, and determine whether biogas-related process changes were financially advantageous.

The solution provided both technical analysis and practical insight, turning monitoring into decision support.

Implementation
  • During two experimental periods, Rodan analyzed consumption patterns and compared them to predicted baseline use. The analysis showed that actual use was well below target during the intervals June 23 to July 16 and August 16 to September 16. The latter period produced estimated savings of approximately 13,000,000 SCF of gas, or about $130,000 assuming $0.01 per SCF.
  • Rodan also identified a separate period of best practice between July 17 to August 15 and September 17 to October 31, during which the client saved an additional 400,000 SCF, representing approximately $40,000 in savings. The identified event suggested a payback period of just 2.5 months if those practices could be repeated consistently.
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IndustrialDemand ResponseMarketIQPeakIQ

How an industrial corporation that produces aluminum generated $10M+ through demand response in New York

New YorkNYISO
Demand response - New York case study
$10M+
earned since 2021
55 MW
manually curtailed during SCR events
10-minute
spinning reserve participation
20+ years
of demand response market participation
The Challenge

Aluminum smelting is one of the most energy-intensive manufacturing processes in the market. For Alcoa, controlling energy cost per kilogram produced is critical. Because the facility is such a large energy user, even small improvements in demand response strategy or curtailment execution can create meaningful economic impact.

Alcoa needed a partner that could help it navigate NYISO demand response programs, reduce operational complexity, and improve both execution and revenue outcomes without compromising reliability.

Our Solution

Aluminum smelting is one of the most energy-intensive manufacturing processes in the market. For Alcoa, controlling energy cost per kilogram produced is critical. Because the facility is such a large energy user, even small improvements in demand response strategy or curtailment execution can create meaningful economic impact.

Alcoa needed a partner that could help it navigate NYISO demand response programs, reduce operational complexity, and improve both execution and revenue outcomes without compromising reliability.

Implementation
  • Rodan worked with Alcoa to align curtailment strategy with its highest-energy processes, particularly the facility’s potlines. For the 10-Minute Spinning Reserve (DSASP) program, Rodan’s automated signals were interpreted by Alcoa’s system to reduce pot room power within seconds. For SCR, Alcoa manually curtailed power during scheduled events, typically reducing 55 MW over a four-hour block.
  • Rodan supported both the technical and commercial side of participation, helping ensure consistent delivery, timely payments, and responsive support throughout the program lifecycle.

Rodan has consistently delivered excellent customer service. The revenue split is outstanding, payments are always timely, and they’re highly responsive to any technical issues. It’s been a game-changer for us. Our experience with Rodan Energy has been the best of any third-party provider we’ve partnered with during our 20 years in the demand response market. The service, support, and financial returns have exceeded our expectations.

Mitch Nemier, Power and Energy Manager
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GovernmentDemand Response

How a major Municipality in Ontario scaled demand response across 22 sites

OntarioIESO
Demand response - Ontario - Case Study
22
sites enrolled in the program
5+ MW
of combined demand response capacity
$1M+
received as of 2016
2.79M
citizens supported through uninterrupted municipal operations
The Challenge

The city faced a common challenge for large public-sector organizations: it had significant demand response potential, but not a simple path to activating it. City staff needed to understand which assets could safely shed load, which facilities had backup generation appropriate for participation, and how to maintain service continuity during event periods.

The city also needed practical support during enrollment and dispatch periods, including event alerts, program guidance, and confidence that facilities could continue to serve residents during participation.

Our Solution

Rodan provided a full demand response assessment and enrollment strategy tailored to a distributed municipal portfolio. The team prescreened city assets, identified sites capable of shedding load, and recommended where existing generation assets could best support participation.

Rodan also provided the operational structure needed to support participation, including program guidance, event notification support, and practical recommendations that aligned energy management with service continuity.

Implementation
  • Rodan first assessed the city’s site portfolio and existing generation capacity to determine which facilities were best suited for demand response participation. Following that assessment, 22 sites were enrolled in the program for a combined demand response capacity of more than 5 MW.
  • Rodan supported the city through the enrollment process and ongoing participation, ensuring city staff understood the process and received notice when demand response events were likely. This helped the city participate without compromising essential services.
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