Smart Manufacturing Suitefor the Sugar Industry

At-a-glance information on PLF on any device, anytime, anywhere

Introduction

Sustainable use of agro-based renewable resources like sugar cane demands the establishment of a complete manufacturing value-chain comprising of sugar as well as other value-added by-products such as exportable power from bagasse, alcohol and ethanol from molasses, biogas and bio-fertilizers from spent wash.

In a typical multi-plant operation setup, controlling losses and ensuring increased productivity is possible for an enterprise only if relevant manufacturing information is available on any device, anytime, anywhere.

If you have a typical multi-plant sugar complex, EcoAxis' solution will help you control losses and ensure increased productivity by making manufacturing information available to you on any device, anytime, anywhere - at your fingertips.

Manual and conventional logging of data is difficult to compile owing to the massive scale of data involved in the operations of an integrated sugar complex. This calls for a Machine-to-Machine (M2M) based monitoring solution that tracks critical parameters of operations and production output on a minute-by-minute basis – or even faster. This compilation is followed by automated analytics and management of the plant through online reports, alerts – very much like internet banking.

How we can help you – EcoAxis solution

IoT based monitoring involves:

• Selecting parameters: Critical process parameters, equipment operations, run-hours, stoppages etc.Intermediate & final products of production: cane crushed, juice, molasses, spent wash and bagasse, sugar andpower – produced, consumed, exported, ethanol production, utilities consumption etc.

• Consolidate data from automation systems through UDAN (Unified Data Access Network): Acquiring & integrating data from DCS, PLC, instrumentation and sensors, etc.

• Configuring and deploying algorithms/alerts: Based on users’ roles & needs reports, dashboards, alerts etc. can be developed.

Do you face these challenges?

• Enhance production and PLF (Plant Load Factor) while reducing losses.

• Ensure high plant availability in a seasonal crushing scenario through reduced break-downs, enhanced productivity, reduced costs/losses, and improved quality.

• Optimize sugar recovery, water usage, power exports and energy usage.

• Limited access to top management for accessing shop floor data on any device, anytime, anywhere.

• Consolidate critical manufacturing data from a multitude of automation systems across the sugar complex (sugar, distillery, co-gen and bio-gas) in a unified manner, which is crucial for technicians and operation managers to provide effective interventions and support to avoid plant downtime.

• Linking agro-based information such as area under cane cultivation, area harvested and cane delivered, cane and sugar yields etc., with production scheduling and manufacturing data in order to operate an integrated sugar complex in an effective and efficient manner.

Solution architecture

KPIs & Advanced AnalyticsData Management

Define user roles

Create users

Functionality

a sxi EYE

a sxi EYE a sxi GURU

a sxi NOTIFYAlerts & Notifications

Application

Server

Database

Server

Configuration

Organisation Users Sites Equipments

• End User

• O & M

• OEM

• Operator

• Maintenance Team

• Management (KPIs)

OPC Client

AxislogData Logger

ERP

Data Acquisition

Weighing System

Milling Section

Boiling House

Boiler House

Energy Meters

Boilers

Energy Meters

Balance of Plant

Turbine

Su

gar

Pla

nt

Co

gen

Pla

nt

Dis

tillery

Rectified Spirit

Energy Meters

Ethanol

ENA

Energy Meters

Flow Meters

Plant

Customer Scope

Bio

gas

EcoAxis’ Solution

Trending Tabular

Data

Export

to Excel

Export

to PDF

What can you achieve with IoT based continuous monitoring system?

• Ability to do in-depth analysis of production, productivity, availability and losses

• Ensuring increased production with high crushing through high mill capacity utilization.

• Optimal balance of sugar rendement (recovery) and sugar production on one hand and better production of alcohol in distillery on another hand, by controlling imbibition water addition as per the business need.

• Better control over production cost by monitoring thermal energy and electrical energy consumption per ton of cane crushed.

• Improve efficiency of multiple equipment across the sugar complex and SMSs/alerts to be generated asneeded.

• Operational load patterns on mill electrical motors against cane preparation, imbibition water consumption pattern in the sugar plant, and steam consumption pattern across sugar and distillery plants, are recorded continuously.

• Improved availability and maintenance by controlling and effectively managing unscheduled stoppages.

• Other benefits ٥ Reduced travel to site ٥ Bringing in more accountability in operations ٥ Ability to analyze through year-on-year, month-on-month performance comparison

Enable quick communication from the dashboard interface through

email and SMS alerts

Identify & rectify any abnormalities in operating patterns such as sudden

increases in electrical load in milling section, sudden variations in steam

demand, irregularity in fuel supply, etc.

Access up-to-date data of production, plant availability, productivity and losses

A.T.E. ENTERPRISES PRIVATE LIMITED

T-126, T Block, MIDC, Bhosari, Pune 411 026T | +91 20 3088 1100 E | contact@ecoaxisindia.comW | www.ecoaxisindia.com / www.ateindia.com

(Business Unit: ) EcoAxis

Waste watereffluent disposal

monitoring

Continuous Measurement &

Verification (CMV)

Analytics for renewable

energy

Discrete equipment monitoring

Facility monitoring

Utilities monitoring

Plant process monitoring

Understand your most critical challenges

Setup systems to collate the most pertinent data

Data acquisition & historization

Build advanced analytics

Generate insights for better decisions

Cloud based platform

EcoAxis Solution

Manual Entry

Trending Tabular

Data

Export

to Excel

Export

to Pdf

ax si EYE - Historian

EcoAxis Hardware

OPC Client

Process 1

Process 2

Process 3

Process n

Basic Functionality

Additional Information

Any device, Anytime, Anywhere

Alerts & NotificationsAnalytics

GURUax si NOTIFYax si

Your Scope Our Solution

Process 4

Data Acquisition Data Management Advanced Analytics