Read-only, over its own 4G link
Small Plantelligence gateways read the signals your meters, sensors and DCS already produce over Modbus, RS485 and OPC, strictly read-only. Data travels securely over 4G to the cloud, and the dashboard is the result.
There is no shutdown, no rewiring of control logic and no dependence on plant IT. The same approach is running today under strict no-modification rules on port-crane PLCs.
Energy & utilities
Live kWh per kg, per batch and per grade.
Batch intelligence
Every batch compared with your golden batch.
OEE & TPM
Loss trees built automatically from run signals.
Machine health
Vibration and temperature on rotating assets.
Safety & ETP
Gas points, tank pressure, effluent quality.
Tank farm
Days of cover and nightly SAP reconciliation.
From a monthly bill to a live cost meter on every tonne
Plantelligence meters each section of the plant and shows energy per kg, per batch and per product grade as it happens. The moment something runs when it shouldn't, such as an agitator on an empty reactor or a chiller fighting an open valve, it raises a flag with the rupee value attached.
Business link: true energy cost flows into each grade's costing sheet, so pricing and scheduling become data-driven decisions.
Every batch compared with your best batch, live
Your history contains golden batches, the runs that went perfectly. Plantelligence learns that fingerprint of temperature curve, pressure and cycle timing, and watches every running batch against it.
If a batch starts drifting, the team hears about it hours before the QC lab would, while there is still time to correct it. One saved batch typically pays for months of the platform.
- Plain-language guidance with the likely cause
- Automatic consistency scorecard for every batch
- Evidence for export customer audits
Your TPM culture, minus the paperwork
Most plants track losses, stoppages and availability by hand, in registers and Excel. Plantelligence captures the run/stop status of equipment automatically from its electrical signature or run signal, and builds the OEE numbers and loss trees your kaizen circles need.
Instead of debating whose register is right, the team opens the screen and goes straight to countermeasures, biggest bar first.
Fix it on Saturday, not mid-batch on Tuesday
A transfer pump failing in the middle of a batch can lose the whole batch plus emergency repair. Machines warn before they fail: vibration rises, bearings run hot, motors draw odd current. Small sensors on critical rotating equipment turn those whispers into a simple message: this machine needs attention in the next two to three weeks.
Continuous proof of what you stand for
An independent watch layer covers gas detection points, tank-farm temperature and pressure, and effluent treatment water quality. Readings are logged 24×7 with instant alerts and audit-ready records. It keeps watching during DCS maintenance, power events or network issues, over its own 4G link.
When the pollution control board, a Responsible Care audit or an export customer asks for evidence, the monthly return is already drafted.
| Zone | Gas | Reading | Status |
|---|---|---|---|
| Butadiene sphere | C₄H₆ | 0% LEL | Normal |
| Styrene day tank | Styrene | 0% LEL | Normal |
| Unloading bay | ACN | 0.4 ppm | Normal |
| Reactor hall north | VOC | 1.1 ppm | Normal |
Know your stock without climbing a ladder
Every day of imported raw material is working capital, and every surprise shortage is a production risk. Level sensors read each tank continuously and translate litres into days of production cover. Physical stock is reconciled against SAP every night, and the purchase team is nudged when a material approaches safety stock.
| Material | Sensor MT | SAP MT | Variance |
|---|---|---|---|
| Butadiene | 312.4 | 314.0 | −0.5% |
| Styrene | 186.9 | 186.2 | +0.4% |
| Acrylonitrile | 64.2 | 67.8 | −5.3% |
Prove value in one area in 8 weeks, then scale
Start small, with success criteria agreed in advance. Expand only when the savings show up on your P&L.
Weeks 1–8 · See the money
Energy meters on major sections, live kWh/kg by grade, tank-level sensing, idle-run and night-load alerts in ₹. Zero touch to DCS.
Weeks 9–20 · See the process
Read-only tap into DCS historians, golden-batch watch on 1–2 grades, automatic OEE, health sensors on 6–8 critical assets.
Week 21+ · See the business
Second plant on the proven template, safety and effluent watch, cost-per-tonne board dashboard, AI monthly narrative.
See what your plant data can tell you
We start with an 8-week pilot on one area, read-only, with no shutdown and no change to your DCS.