Research by BHAG Digital Co-founder and CEO Vitalii Haleliuka Published at Cable & Wire 2026

On 27–28 October 2026, Mumbai, India, hosted the 10th international Cable & Wire 2026 conference and exhibition, dedicated to modern technologies, innovative solutions and the future of the cable industry.

At the conference, Vitalii Haleliuka, Co-founder and CEO of BHAG Digital, presented a technical research paper on improving energy efficiency in cable manufacturing through digital technologies. The paper was published in the official conference proceedings, and its author received the Technical Paper Author award from the event organiser, IEEMA.

Data-driven energy efficiency in cable manufacturing

The technical paper “Energy per Kilometre: Physics-Based Baselines and a Data-Driven Energy Agent for Cable Manufacturing” examines an approach to measuring, analysing and optimising energy consumption at cable plants.

One of the key challenges in modern manufacturing is tracking electricity consumption for specific finished products as well as overall electricity use. This is particularly relevant to cable manufacturing, where different cable types require different processes, equipment and amounts of energy.

The study proposes a method for calculating electricity consumption per kilometre of finished cable (kWh/km). It combines line-level energy measurements, equipment operating states and production data from BEEDIGIT MES.

This approach enables a more detailed analysis of process energy efficiency, helps identify unproductive consumption and provides more accurate energy indicators for different cable products.

Energy Agent: intelligent support for energy management

The paper focuses on the Energy Agent concept, a decision-support system that uses production data to identify energy deviations and recommend improvements to equipment operation.

Energy Agent considers the production schedule, current machine states, expected idle periods and energy consumption. It can use these inputs to recommend suitable standby modes, help detect abnormal electricity consumption and identify opportunities to reduce energy costs.

The proposed approach uses production information that a plant’s digital systems may already collect, without requiring separate meters for every production order.

Research findings and energy-saving potential

The method was evaluated through a 26-week simulation of a cable plant producing several types of cable.

Under the specified assumptions, the simulation indicated potential electricity savings of approximately 8.3% and electricity cost savings of approximately 9.3%.

The main contributors were improved equipment standby modes, consideration of the production schedule, timely detection of energy deviations and more efficient use of energy resources.

The author emphasises that these figures come from computer simulation rather than measurements at an operating plant. The next research step is to validate the method using real production data.

BEEDIGIT’s role in digital cable manufacturing

BEEDIGIT technologies, which collect, process and analyse production data, are an important component of the approach.

BEEDIGIT IoT solutions provide information on machine operation, equipment states and energy consumption. BEEDIGIT MES complements these inputs with production orders, output quantities and the actual execution of manufacturing operations.

Combining these data creates a foundation for detailed analysis of production-line efficiency, the identification of hidden energy losses and the development of intelligent production-management tools.

The study illustrates a promising application of industrial digital technologies: moving from machine monitoring to decision-support systems that help manufacturers use resources more efficiently.

Publication in the Cable & Wire 2026 proceedings

Vitalii Haleliuka’s full technical paper appears in the official proceedings of the 10th International Conference & Exhibition on Cables, Wires & Accessories, Cable & Wire 2026, pages 270–279.

The conference and research publication provided an opportunity to present the work of the BHAG Digital, Factory Online and BEEDIGIT team to the international cable-industry community.

We continue to develop digital solutions for industrial companies, explore new uses of production data and implement technologies that improve the efficiency and transparency of manufacturing processes.

Related reading: Smart Cable Manufacturing — Wire & Cable Poland 2025.