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Beyond the Hype: What Closed-loop Applications Actually do

By
Gary Bourton

"You can’t fix what you can’t see”. That’s what the plant director told me as we were standing in a brick works beside a smouldering kiln, data monitors flickering around us. Their team had been chasing efficiency gains for years, tweaking firing curves, adjusting fuel feed, battling thermal drift. Yet day after day, bricks still came out uneven, energy still soared.

Sounds familiar? In manufacturing, it’s never the obvious mistakes that keep you up at night. It’s those sneaky blind spots, the hidden inefficiencies quietly whittling away your performance. That’s where Autonomous Intelligent Operations (AIO), also known as closed-loop systems, significantly increase efficiency.

A Copilot for Complex Operations

Think of AIO as your behind-the-scenes detective. It’s always on the lookout for the tiny oversights that usually go unnoticed. The silent troublemakers causing your biggest headaches. And the best part? AIO doesn’t just find these problems; it fixes them before they start costing you.

What truly sets AIO apart? It handles complex challenges with the speed and precision of an experienced Ops manager. Often even faster and more accurately than a human ever could. Consider the millions of moving parts and decisions involved in your complex manufacturing processes. AIO applies expert-level logic to every single one, turning chaos into clarity.

But it doesn’t stop there. Whether you’re talking predictive maintenance, hyper-personalised recommendations, or spotting anomalies nobody else can see. AIO pulls powerful insights from your mountain of data enabling you to make smarter, faster decisions and keep your operations running smoother than ever.

With AIO, you’re not just managing manufacturing. You’re outsmarting obstacles before they appear.

Back to the Plant Floor

Let’s head back to the brickworks to bring the impact of AIO to life. Today you’ll see AIO continuously ingesting live data, temperature, pressure, fuel input, material moisture, to name but a few data points. It applies models that detect inefficiencies, inconsistencies or costly drift.

And then the magic happens. It acts. Not in a month. Not next week but in real time.

Fuel-to-air ratios are adjusted automatically. Firing curves are fine‑tuned and moisture content optimised, all without human intervention.

AI keeps operations permanently inside optimal parameters 24/7. Something no team, however experienced, can sustain on their own. Resulting in tighter quality, reduced variability and lower energy consumption.

Every day is a school day for AI. It learns continuously, making adjusts as raw materials vary or fuel blends and seasons change. This isn’t rigid automation. It’s adaptable intelligence.

Rest Easy the Robots aren’t Taking Over

Having waxed lyrical about the benefits of AIO over human limitations, let’s address the first elephant in the boardroom. Automation anxiety is real. Staff fear losing their jobs. AIO platforms augment rather than replace human experience. They free up operator time to focus on higher value work. Meaning, operators spend less time chasing alarms or manually adjusting parameters and more time on process improvement, quality oversight and predictive maintenance. They become decision makers not firefighters,

In many cases, better plant performance leads to more shifts, not fewer jobs. Higher performance related bonuses and the funds to reinvest in upskilling the workforce. All of which create a better employee experience, improving retention and engagement.

ROI, Express Delivery

Onto the second elephant. Boardroom scepticism around AI is real and rightly so. We’ve all seen the slick presentations promising digital transformation. But reputable studies bust the myth that AIO requires high capex and yawningly long ROI timelines. Well implemented AIO systems can generate returns within weeks or months, not years. Here’s a small sample of recently published evidence.

In a cross-sector report, KPMG found that manufacturers integrating AI agents for autonomous production lines and supply chains achieve rapid efficiency gains. Sectors cited include ceramics and traditional process industries, where AI-driven process parameter optimisation, real-time defect detection, and autonomous scheduling yield measurable cost and waste reductions. Case studies note shifts from weeks- to days-scale payback as defects and downtimes drop. [1]

Another, hot-off-the-press, report concludes that AI adoption significantly reduces energy intensity in manufacturing, reinforcing its role as a key lever for energy savings and sustainability. [2]

Similarly, a separate review of the evidence, including McKinsey case studies, found AI-powered demand forecasting and scheduling reduce inventory costs by 20% and improve on-time delivery by 25%. With manufacturers typically seeing payback within the first 6–12 months and substantial revenue gains. [3]

Added to which, operational disruption during deployment is low because these AI platforms layer over existing MES or SCADA systems. Typically, trials start on one kiln or line and are further rolled out once the ROI is clear. Most systems go-live in under 12 weeks.

Together these studies highlight consistent themes, between 5 –10% efficiency gains across energy use, throughput, and quality. This amounts to six or seven figure savings annually for UK process manufacturers.

The shift to outcomes‑based pricing

There’s more good news to be found in a growing AIO trend to pay for performance, not just licences. You pay only if the AI delivers measurable efficiency gains, energy savings, or emissions reductions.

This aligns risk with value and lowers the perceived financial barrier for mid-sized operators keen to trial advanced AI without heavy capex. In effect, de-risking innovation in cautious, energy‑intensive industries.

A strategic imperative for UK process manufacturers

With unstable energy prices, pressing net‑zero targets, and squeezed margins, its time, as an industry to lay down any scepticism we may harbour toward AIO. Take a closer look at the evidence to better understand its capability to deliver rapid, measurable ROI, scale with minimum disruption, performance resilience and environmental sustainability.

References

  1. (2025, KPMG) Intelligent manufacturing: A blueprint for creating value through AI-driven transformation
  2. (2025, Energy Economics, Elsevier) Does artificial intelligence reduce energy intensity in manufacturing? Evidence from country-level data
  3. (2025, J. Rajaram) What is the real ROI of intelligent automation in 2025?

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Why "Idle Power" Is the Largest Untapped Lever in Data Centre Decarbonisation

Jordan Toulson
June 29, 2026
5
min read

Your servers burn up to 30% of their power budget doing nothing. Whilst your team chases renewable contracts and cooling upgrades, idle CPUs are quietly consuming capacity you need for growth. CPU power-state optimisation delivers immediate savings from existing hardware: no new builds, no refresh cycles, no waiting.

Data centre managers face a familiar paradox: sustainability roadmaps are lengthening whilst power constraints are tightening. Your board wants aggressive carbon targets. Finance wants lower OpEx. Meanwhile, AI workloads and digital transformation are queuing up for capacity you don't have.

The conventional approach -renewables contracts, PUE optimisation, next-generation cooling - remains essential. But these infrastructure investments are capital-intensive, take years to deploy, and often deliver diminishing returns. A more immediate decarbonisation lever sits hidden in plain sight: the CPUs already in your racks.

The problem hiding inside your servers

Here's what most capacity plans miss: a server sitting idle still burns 40–70% of its peak power. [1] Research confirms that even at single-digit utilisation, conventional servers draw roughly half their maximum load. More recent designs have improved at the extreme low end: true idle consumption has fallen from 51% of peak in 2014 to around 36% today. [2] But “better” is not the same as “fixed" because the power curve remains stubbornly non-linear at low utilisation.

Even with modern servers, a drop to ~10% utilisation doesn’t translate into anything like a 90% reduction in power. Consumption often remains closer to ~50% of peak, meaning you’re still paying for electricity and emitting carbon for processing capacity you’re barely using. [2,3] Across a typical enterprise or colo fleet averaging 20–30% CPU utilisation, the idle overhead compounds into a substantial and largely hidden waste stream.

For data centre leaders juggling reliability, cost and carbon mandates, this idle draw functions as a growth tax. It consumes power headroom needed for resilience buffers, hardware refresh cycles and new workload onboarding. In colo environments with contracted power caps, it directly limits expansion. Even worse, because it doesn't show up as a utilisation problem, it rarely triggers action until the electricity bill forces a reckoning.

Why traditional efficiency measures can't solve this

While PUE improvements target everything around the server - chillers, airflow, lighting - they can't address inefficiency inside the chip. A facility with a stellar PUE of 1.1 still wastes watts if its CPUs are drawing 60% power at 5% load. Renewables reduce the carbon intensity of your energy, but they don't reduce the amount you're consuming. In markets with constrained grid capacity or time-of-use pricing, that distinction matters.

Virtualisation and consolidation help by redistributing workloads, but you're still running servers that burn energy disproportionate to their output.[4] Without addressing the power-to-utilisation mismatch at source, these strategies simply redistribute the problem rather than eliminate it.

The at-source solution: CPU power-state optimisation

Modern x86 processors support fine-grained power management through P-states and C-states.[5,6] When configured correctly, these mechanisms allow CPUs to scale power consumption much more closely with actual demand.

The impact is significant. Intel and QiO jointly validated results showing up to 52% idle power reduction and approximately 24% savings under representative load.[7] Breakthrough research from Huawei and ETH Zurich introduced enhanced deep C-states that cut idle power to just 5-7% of active draw, reducing energy consumption for Memcached workloads by up to 71%, with less than 1% performance degradation.[8,9]

In practice, realistic fleet-wide savings fall in the 20–30% range for overall data centre CPU energy consumption. That's achievable with existing hardware, no hardware replacement required.

Immediate deployment, zero disruption

Changes can be deployed via firmware and infrastructure management systems without racking new hardware, avoiding lengthy procurement cycles. [10,11] In live operations, power-state optimisation is a balancing act. Deeper savings can introduce small increases in wake latency as CPUs exit low-power states, typically measured in microseconds, so configurations should be set to match the latency tolerance of each workload and SLA. You’re tuning assets already deployed, not financing new builds. And because lower server power reduces heat output, it cuts cooling demand too, improving PUE and extending UPS runtime, creating a compounding efficiency gain across the infrastructure stack.

For data centre leaders under pressure to deliver more with less, this is the rare initiative that cuts costs, frees capacity and accelerates decarbonisation simultaneously. It's demand reduction at source, not offsetting down the line.  

Start with what's already plugged in

The narrative that renewables and PUE solve everything no longer holds in an era of constrained power and accelerating demand. CPU power-state optimisation is emerging as a critical efficiency enabler and, if neglected, a hidden cost multiplier.

The path to net-zero shouldn't begin with what you'll build in 2027. It should start with optimising what's already plugged in. CPU power-state management isn't a substitute for renewables or infrastructure modernisation; it's the foundation that makes those investments more effective by shrinking the baseline load they need to serve.

For data centre operators, aligning server-level power management with capacity and carbon objectives is no longer optional. It's a prerequisite for unlocking the full return on infrastructure investments and ensuring long-term operational, financial and environmental sustainability.

In a world where power is the new square footage, idle servers are an unaffordable luxury. The largest untapped lever in data centre decarbonisation isn't outside your facility; it's inside every rack.

References

[1]: Meisner, D. et al. PowerNap: Eliminating Server Idle Power, Stanford University.
[2]: (2023) Power Proportionality and Idle Power Consumption of Servers, David Kopp Notes.
[3]: (2024) What is the Relationship Between Server Utilization Rates and Energy Consumption?, Sustainability Directory.
[4]: Sharma, S. (2016) Trends in Server Efficiency and Power Usage in Data Centers, SPEC.
[5]: (2024) Understanding the Concept of CPU Power States, Livewire Development.
[6]: Processor P-states and C-states, Thomas-Krenn.
[7]: (2023) Power Management: Leveraging AI for Smarter Data Center Power Efficiency, Intel Network Builders.
[8]: (2023) AgileWatts: Sustainable Server Design for the Modern Data Center Era, arXiv (Huawei/ETH Zurich).
[9]: (2022) AgileWatts: Sustainable Server Design for the Modern Data Center Era, IEEE Xplore.
[10]: (2023) Enhanced Power Management for Low Latency Workloads Technology Guide, Intel Network Builders.
[11]: (2024) Power Management and Energy Efficiency in Data Centers, Cisco Live.

Four Questions Standing Between You and 25% Server Energy Savings

Jordan Toulson
April 15, 2026
5
min read

Fitting the system beats rebuilding it every time. While autonomous server energy optimisation delivers 19 to 29% power savings without new hardware, grid upgrades or major retrofits, the word “autonomous” prompts four key questions DC leaders should be ready to answer.

Many approaches to cutting data centre energy costs involve spending money to save money. New cooling systems. Hardware refreshes. Renewable energy contracts. They all work, but they all take time, capital and sign-off from people who’d rather not spend money of that magnitude. And with projects like these, the return on investment is typically measured in years, not months.

Against this backdrop it’s easy to see why autonomous server energy optimisation is fast attracting interest as an alternative proposition. It fits into your existing infrastructure. No new hardware. No construction. No waiting for grid connections. And critically it uses what you already have, to deliver proven energy savings of 19 to 29% server power reduction under varying loads [1] and up to 25% savings under representative workload [2]. And because solutions like these typically run on a SaaS model, the ROI has to deliver within months, not years. Because if it doesn’t deliver, you don’t renew.

While that’s an attractive proposition the word “autonomous” can make leaders uneasy for understandable reasons. If you are preparing to brief your board on autonomous server energy optimisation here are four questions the board are likely to ask.

4 Questions a Board Will Ask About Autonomous Energy Optimisation

1. “What if it causes an outage?”

Your SRE and reliability teams will raise this first, and rightly so. The benchmark to look for is a hard, automatic threshold. A well-designed autonomous optimisation tool won’t wait for a human to intervene. If CPU utilisation breaches a set limit, the optimisation system shuts itself off and reverts the server to its default settings. No delay. No escalation required. That’s the difference between genuine autonomy and tools that just make recommendations. The guardrail isn’t bolted on afterwards. It’s how the technology works.

2. “How do we know what it’s doing, and can we audit it?”

Ops, engineering and compliance all want the same thing – visibility. Any solution worth considering should log every action taken while enabled. Look for a clear record of what was changed and when, accessible to your team without needing to ask the vendor for it. That provides compliance with an evidence trail without the need to maintain a separate register.

3. “Who controls it?”

In any well-run data centre, server-level access sits with the IT team and SREs, governed by role-based access control under ISO 27001. What matters is that those with access can pause or disable the optimisation at any point, and the system reverts cleanly when they do. That operational confidence is what keeps teams running autonomous tools rather than switching them off after the first week.

4. “Who owns the outcomes?”

Finance and sustainability will want to know who reports the savings and who is accountable if something goes wrong. The answer is a lightweight governance framework, not a six-month programme. Three tools should do the job. An ownership matrix that maps decision domains with no ambiguity on accountability. Second, an incident review loop for regular assessment of outcomes and near-misses. And third, a review of the system’s own action logs as the evidence base.

The bigger picture

None of these questions should kill the conversation. They all have evidence-backed answers [1][2][4], and that’s what makes autonomous optimisation worth serious consideration. When evaluating solutions, the things to insist on are built-in thresholds, automatic rollback and full action logging as standard.

In the current geopolitical climate, data centre energy costs won’t be going down for some time, and neither will grid constraints ease. The organisations that act first on fitting rather than rebuilding will be the ones with headroom when it matters most.

If you’d like to see what autonomous energy optimisation could deliver across your estate, we’re happy to walk you through the evidence and explore whether it’s a fit for your environment.

References

1. (2023) Using AI to Reduce Energy Consumption, Cost and Carbon Emissions in Data Centres, WWT.

2. (2022) Power Management: Leveraging AI for Smarter Data Centre Power Efficiency, Intel / Network Builders.

3. (2017) Know When to Use Open- or Closed-Loop Control, Control Engineering.

4. (2026) Data Centre Energy Optimisation at Scale: Why Manual Tuning Can’t Keep Up, QiO Technologies.

Cut Energy Use, Not Cyber Defences

Jordan Toulson
March 31, 2026
5
min read

The UK Cyber Security and Resilience Bill will make cyber compliance mandatory for data centres. At the same time, energy costs are pushing operators towards optimisation tools that rely on cloud connections and external APIs. That’s a problem, because every new external dependency widens the attack surface you’ll soon be assessed against. There’s a way to cut server power without creating a compliance liability.

The rules are changing

The UK Cyber Security and Resilience Bill is currently making its way through parliament and will bring data centres into scope as essential services for the first time. Standalone facilities above 1 MW and enterprise sites above 10 MW will face mandatory cyber security and operational resilience requirements, with Ofcom as the regulator. Penalties for non-compliance run up to £17 million or 4% of global turnover, plus daily fines of up to £100,000. If you operate in the EU, NIS2 and DORA are already in force. This isn’t coming over the horizon. It’s here.

The energy problem hasn’t gone away

At the same time, energy consumption is rising, regulation is tightening [1][3], and costs are soaring. It makes sense that data centre leaders are turning to tools to optimise energy management. Unfortunately, most of those tools need a cloud connection, an external API, or a hosted pipeline to work. In an environment where 74% of large UK businesses were hit by a cyber breach last year and supply-chain compromises have doubled [2], each new external dependency is something you’ll need to account for under the incoming regime.

SolarWinds showed us what happens when infrastructure tools with deep network access phone home. Privileged access to everything, and its outbound connection became the entry point for one of the worst supply-chain attacks on record.

Optimisation without the exposure

But what if the optimisation tool didn’t need an outbound connection at all? Design it to run entirely on-prem, by default, and you remove the attack surface rather than trying to manage it. Everything stays inside the data centre boundary: the telemetry collection, the AI that decides what to do, and the control actions themselves. The system monitors workload levels only, not what that workload is. Nothing leaves your network unless you choose it to.

For example, each instance of ServerOptix includes a local dashboard on the server where it’s deployed, so you can monitor savings without any external connection. If you’re running multiple instances, whether across servers in a single facility or across multiple data centres, an optional cloud-based dashboard lets you aggregate the data in one view rather than checking each instance individually. Either way, the control loop never depends on a cloud connection.

It works in air-gapped environments too. No internet connection required. And rather than a dashboard that tells you what to do and hopes someone acts on it, a closed-loop system senses workload, adjusts CPU power states, and rolls back if performance dips.

Real savings, independently tested

WWT independently measured 19 to 29% power reductions at the PDU, not from onboard telemetry, across Dell R650 and R750 servers. Exhaust temperatures dropped by over 9% [4]. Intel proof-of-concept testing showed up to 25% savings under representative workload and roughly 52% at idle [5]. Live customer deployments have recorded average savings above 29%.

At 2,000-server scale, that’s around 1.146 GWh off your energy bill. The associated carbon savings depend on local grid carbon intensity: in the US, that equates to over 410 tonnes of CO2 saved annually; in the UK, approximately 202 tonnes; and in a low-carbon grid like France, around 30 tonnes. Depending on local energy prices, typical payback periods fall within eight to twelve months.

Built for the compliance environment that’s hoving into view

The energy savings matter, but they only count if the tool can get deployed. That means passing muster with your security and compliance teams. On that front: no new external firewall rules required (depending on your network configuration, internal rules may need updating). No new external access paths unless you opt into optional dashboarding. It sits inside your current network segmentation and is designed to work within existing zero-trust architectures, not against them. All telemetry stays within your monitoring boundary by default. It can contribute to EU EED reporting by providing data on IT-specific power consumption across the servers where it’s deployed, though full reporting coverage would require deployment across all machines in scope [3]. And there’s no external vendor in the data path, which addresses supply-chain risk requirements under NIS2 and the UK Cyber Security and Resilience Bill.

Energy savings that don’t come with a compliance headache

You shouldn’t have to choose between cutting energy costs and staying on the right side of incoming regulation. A fully on-prem, air-gap-ready, closed-loop system lets you drive continuous power reduction without widening your attack surface. With the Cyber Security and Resilience Bill on its way, the smartest time to reduce your energy costs is before the compliance burden lands on top of them.

References

[1] IEA (2025) Energy and AI, International Energy Agency. https://www.iea.org/reports/energy-and-ai

[2] DSIT/Home Office (2025) Cyber Security Breaches Survey 2025, UK Government. https://www.gov.uk/government/statistics/cyber-security-breaches-survey-2025

[3] European Commission (2025) Energy performance of data centres, EU Energy Efficiency Directive. https://energy.ec.europa.eu/topics/energy-efficiency/energy-efficiency-targets-directive-and-rules/energy-efficiency-directive/energy-performance-data-centres_en

[4] WWT (2023) Using AI to reduce energy consumption, cost and carbon emissions in data centres, World Wide Technology. https://www.wwt.com/article/using-ai-to-reduce-energy-consumption-cost-and-carbon-emissions-in-data-centers

[5] Intel/QiO (2022) Power management: leveraging AI for smarter data centre power efficiency (solution brief), Intel Network Builders. https://builders.intel.com/docs/networkbuilders/power-management-leveraging-ai-for-smarter-data-center-power-efficiency-solution-brief-1664790296.pdf

[6] European Commission (2025) Assessment of next steps to promote the energy performance and sustainability of data centres in EU, including the establishment of an EU-wide rating scheme, October 2025.