The joint effort between Stellantis and etalytics has led to up to over 60% greater efficiency and reduction in energy usage for ventilation at its Rüsselsheim plant where Opel and DS Automobiles vehicles are produced, demonstrating the power of AI in optimizing complex industrial systems and marking a significant step towards sustainable manufacturing.
Rüsselsheim/ Darmstadt, Germany, 11.03.2025 – The collaboration between Opel’s parent company Stellantis and etalytics has resulted in reductions in electrical power consumption for ventilation of up to over 60% and a significant decrease in the demand for compression cooling.
Rising energy prices and stricter climate regulations are driving industries to optimize their operations and accelerate their path towards climate neutrality. etalytics’ etaONE platform uses real-time AI analytics to optimize energy use in heating, cooling, and ventilation systems. It helps companies reduce costs, improve efficiency, and lower emissions.
By utilizing etalytics’ etaONE platform, the project has driven energy efficiency improvements and cost savings, while furthering Stellantis’ dedication to reducing environmental impact and improving operational sustainability in their manufacturing processes.
Tackling Challenges in Energy-Intensive Manufacturing
Paintshops are among the most energy-intensive areas in automotive production, with HVAC systems consuming a substantial portion of energy resources. At the Stellantis plant at Opel’s headquarters in Rüsselsheim, the challenge was to reduce this energy consumption while ensuring a comfortable working environment for employees. To address this challenge, etalytics implemented an AI-based operational solution that dynamically adapts to production demands and external conditions.
Demand-driven ventilation at optimum efficiency and intelligent scheduling of fresh air intake during cooler early morning hours have been key to these savings. Leveraging the workshop’s thermal inertia, the system minimizes the need for energy-intensive cooling during the day.
AI-Driven Optimization with etaONE at Stellantis Paintshop
The system operates using etalytics’ etaONE platform, employing energy monitoring and advanced Model Predictive Control (MPC) techniques. This approach continuously evaluates real-time data to optimize ventilation, cooling, and air quality, ensuring that energy is only used when and where needed.
Through etaONE, further opportunities for improvement were identified. For example, optimizing airflow at the fresh air intake could reduce the incoming air temperature by up to 10 K (Kelvin), unlocking even greater free cooling potential with targeted infrastructure adjustments.
“With the expertise of etalytics, we are implementing AI-based operational optimization for the HVAC systems in our production facilities. This transition allows us to move from a static, constant operation to a dynamic, demand-driven, and forward-looking approach. The ventilation can often be completely shut off while still maintaining an improved climate for my colleagues in the workshop. The system runs seamlessly, and I sometimes double-check to ensure the optimization is still active, only to confirm that everything is operating effectively.”– Markus Eckhardt, Electrical Equipment Maintenance Manager, Opel
“With AI at the core of our solution, we’re not only optimizing energy use but also building a system that responds to real-world conditions, from changes in weather to shifting production demands. This creates an operation that’s not just more efficient, but also more resilient – capable of handling challenges as they come.” – Dr. Thomas Weber, Co-Founder & CSO, etalytics
Expansion Plans and Future Goals
Encouraged by these results, Opel Automobile plans to extend the AI-based control software to additional HVAC systems at its Rüsselsheim facility. etalytics is also supporting Opel in pursuing efficiency improvements in cooling generation for HVAC systems. Strategies such as shifting compression cooling usage to times of maximum efficiency are under consideration.
Research-Driven Implementation
The HVAC system optimization was implemented in partnership with the Institut für Produktionsmanagement, Technologie und Werkzeugmaschinen at TU Darmstadt as part of the DiNaPro research initiative. This project highlights the potential of academic and industrial synergies to achieve groundbreaking energy efficiency improvements.
About etalytics
Founded in 2020, etalytics emerged from the “ETA | Energy Technologies and Applications in Production” research group at the PTW Institute of Technical University Darmstadt. The company specializes in AI-driven solutions that help businesses globally optimize energy consumption, reduce costs, and minimize their environmental impact. Its flagship product, etaONE, offers real-time insights and predictive analytics, enabling industries—including data centers, chemical, pharmaceutical, and automotive—to implement effective control strategies and make informed energy decisions. Recognized for its innovative and sustainable approach, etalytics has garnered multiple awards both nationally and internationally. Industry leaders worldwide rely on its technology to achieve significant savings in energy, CO2 emissions, and operational costs.
About Stellantis
Stellantis N.V. (NYSE: STLA / Euronext Milan: STLAM / Euronext Paris: STLAP) is one of the world’s leading automakers aiming to provide clean, safe and affordable freedom of mobility to all. It’s best known for its unique portfolio of iconic and innovative brands including Abarth, Alfa Romeo, Chrysler, Citroën, Dodge, DS Automobiles, FIAT, Jeep®, Lancia, Maserati, Opel, Peugeot, Ram, Vauxhall, Free2move and Leasys. Stellantis is executing its Dare Forward 2030, a bold strategic plan that paves the way to achieve the ambitious target of becoming a carbon net zero mobility tech company by 2038, with single-digit percentage compensation of the remaining emissions, while creating added value for all stakeholders. For more information, visit www.stellantis.com.
About Opel
Opel is one of the largest European car manufacturers and a leader in the reduction of CO2 emissions thanks to its extensive electrification offensive. The company was founded by Adam Opel in Rüsselsheim, Germany, in 1862 and started building automobiles in 1899. Opel is part of Stellantis NV, a global leader created for the new era of sustainable mobility. Together with its British sister brand Vauxhall, the company is represented in more than 60 countries around the globe, continuing to enter new international markets. Opel is currently consistently implementing its electrification strategy to secure sustainable success and ensure that the future mobility demands of customers are met. An electrified variant of each Opel model is already available today.
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