Mosca Malaysia: Energy Monitoring & Monthly Reporting

Mosca's strapping plant in Ulu Tiram, Johor uses CobiNeural to monitor energy in real time, produce its monthly energy report from live data and alert the team when equipment behaves abnormally. The plant no longer depends on a monthly Tenaga Nasional Berhad (TNB) bill and a hand-built spreadsheet to understand its energy use.

The site

Mosca is a German manufacturer of packaging solutions, with nearly 60 years in strapping machines, stretch-wrapping equipment and strapping materials. Its Malaysian company, Maschinenfabrik Gerd Mosca (MGM) Sdn. Bhd., has operated since 2009. In June 2025 it commissioned a state-of-the-art expanded facility in Ulu Tiram, Johor to serve the Asia-Pacific region.

The site follows Mosca's "Nonstop Performance" approach: continuous, dependable production for customers who cannot afford a packaging line that stops. Its energy use is typical of light-to-medium manufacturing. Motors, compressors, extrusion and assembly lines draw most of the power, along with the building services that keep the floor running. Loads like these are common, so they are easy to leave unmonitored until the bill rises.

The problem

Two jobs were hard to do well from the monthly TNB bill alone.

The first was the monthly energy report. Collecting figures by hand was slow and error-prone, and the report was out of date by the time anyone read it. Mosca wants to track consumption trends and be ready for the Energy Efficiency and Conservation Act (EECA) and the ISO 50001 energy management standard. A spreadsheet rebuilt every month is a weak record for either.

The second was spotting abnormal behaviour as it happened. A motor drawing more power than usual, a machine left running outside its schedule, or a load creeping up week by week cannot be seen on the floor. On the bill, these show up a month later, after the cost has been paid.

What we did

Mosca uses CobiNeural, Cobler's Smart Operation Platform, to monitor energy across the plant in real time. CobiNeural runs as an overlay on the plant's existing systems, so Mosca did not have to replace working equipment or stop a production line to install it.

Four parts of the platform do the work:

• Insights to Energy shows consumption, demand and trends for the whole site and for each piece of equipment. The team can see where the kilowatt-hours (kWh) go, instead of reading one total on a bill.
• Insights to Equipment breaks the data down to individual machines. When there is an unusual draw or an off-schedule run, the team can trace it to the machine responsible.
• Alerts notifies the team when consumption moves outside its normal pattern or a machine runs when it should not. The team can check it the same day rather than at the next billing cycle.
• Reporting produces a consistent monthly energy report from live data. The energy team now reviews and shares the report instead of assembling it by hand.

What changed

The team now sees plant energy use continuously. Monthly reporting takes far less effort, and the time between "something looks wrong" and "we have checked it" is much shorter. For a plant built around continuous production, this visibility supports keeping the lines running. It is part of daily operation rather than a separate compliance task.

See how other Malaysian manufacturers handle the same problem in our case studies, or read how CobiNeural works with a site's existing building management system (BMS), programmable logic controllers (PLCs) and SCADA (supervisory control and data acquisition) system.

Want the same visibility for your plant? Book a CobiNeural walkthrough.