Tea: lower cost per kilo of made tea.
Withering is the largest electrical load and the biggest grade lever. Firewood is bought by the stack but burned by energy content.
Where the money goes
Withering fan energy
Fans run flat out all cycle. Scheduling speed and hot air per trough delivers the same drying with a fraction of the power, because fan power falls with the cube of speed.
Firewood by energy, not volume
Wet wood carries far less heat. Checking moisture on every load, pricing suppliers per gigajoule and trimming excess air cuts wood per kilo.
Grade consistency
Drifting wither, fermentation time and dryer moisture push tea into lower grades. PlantOS traces every lot back to the stage that cost it.
What you get
One number per kilo of made tea
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 tea factories?
Typically: RH and temperature probes, Trough load cells, Fan drives, Inline NIR moisture, Flue O₂ analyser, Vibration on CTC drives.
What is the usual first project?
Trough sensors and fan drives on the withering line.
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.