Sugar: lower cost per tonne of cane crushed.
Bagasse should run the whole mill and still export power. Wet fuel, an unbalanced steam house and hidden sucrose losses stop that.
Where the money goes
Steam and bagasse balance
Wet bagasse and excess air waste fuel. A live steam balance shows which evaporator body or heater is taking more than its share.
Sucrose accounted for
Sugar left in bagasse, filter cake and molasses leaves the gate unseen. A live mass balance shows where.
Mill and centrifugal drives
The heaviest motors in the plant. Condition monitoring and load sharing prevent crushing stops in season.
What you get
One number per tonne of cane crushed
Electricity, fuel and losses rolled into cost per unit, live and by section, with hour-by-hour heatmaps that show waste outside working hours.
The right person, at once
Alarms and advice go by SMS, WhatsApp or email to whoever is responsible for that section, and escalate if nobody acknowledges.
PlantOS engineers on every shift
Our intuitive algorithm learns what normal looks like for every signal and flags abnormal events as they happen; our engineers review each section's data and send you advice and a one-page weekly report.
Questions
What does PlantOS measure in sugar mills?
Typically: Steam flow meters, Flue O₂ analysers, Inline Brix and pol, Turbine and drive power, Vibration on mills, Bagasse moisture.
What is the usual first project?
Steam and condensate balance across boilers and evaporators.
How are savings proven?
A baseline of energy against production is fixed before changes are made; savings are the difference between what the baseline predicts for each day's production and what was measured, in line with IPMVP Option B.
Find the shillings hiding in your plant.
See a live plant in your sector, then a 30-day plant assessment with a report in shillings per unit. No line stoppage.