One platform. Tuned to your process.
Every industry hides money in different places. PlantOS maps your process line, measures cost in your own unit, and starts where the payback is fastest.
Tea
Cost tracked per kilo of made teaWithering is the largest electrical load and the biggest grade lever. Firewood is bought by the stack but burned by energy content.
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.
Sugar
Cost tracked per tonne of cane crushedBagasse should run the whole mill and still export power. Wet fuel, an unbalanced steam house and hidden sucrose losses stop that.
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.
Dairy
Cost tracked per litre processedRefrigeration is the biggest electrical load, cleaning runs longer than it needs to, and milk goes missing between tanker and pack.
Refrigeration efficiency
Cooling output per kilowatt shows fouled condensers, wrong setpoints and refrigerant loss long before product temperature drifts.
Cleaning cycles
Conductivity, flow and temperature data trims each CIP cycle to what it actually needs: less water, heat and chemical.
Milk accounted for
Litres in versus product out, per shift, exposes line, rinse and changeover losses.
Grain milling
Cost tracked per tonne milledPneumatic conveying fans and roller mills dominate the bill, and a fraction of a percent of extraction is worth more than most energy projects.
Conveying fans
Often the largest load in a mill and rarely speed-controlled. Drives matched to demand cut power sharply.
Extraction rate
More flour from the same wheat. A daily balance of wheat in and products out shows each mill’s real extraction.
Energy per tonne
Kilowatt-hours per tonne per mill flags worn rolls and poor settings before quality complaints arrive.
Beverages
Cost tracked per hectolitreBreweries, soft drinks and water plants spend on refrigeration, compressed air and CO₂, and lose capacity to micro-stops.
Utilities per hectolitre
Refrigeration, steam, compressed air and CO₂ per hectolitre show exactly which utility drifted and when.
Compressed air
Packing lines leak air constantly. Leak tracking and pressure reduction often pay back within months.
Line efficiency
Micro-stops on fillers and labellers are hidden capacity. Every stop logged with its cause and its cost.
Edible oils
Cost tracked per tonne refinedSteam and thermal oil run on fixed setpoints, vacuum systems drift unmeasured, and oil leaves in by-products.
Steam and thermal oil
Load-matched heater control and steam-trap monitoring cut fuel without touching the process.
Refining losses
Oil lost in meal, soapstock and fatty-acid distillate, accounted for batch by batch.
Vacuum and cooling
Steam ejectors and cooling towers lose efficiency quietly. Measuring them shows when to service.
Cement & lime
Cost tracked per tonne of cementGrinding mills and very large fans dominate electricity; kiln stability decides fuel per tonne of clinker.
Mill energy per tonne
Live kWh per tonne per mill catches poor loading and worn media the same shift.
Kiln and cooler fans
Huge fans on dampers waste energy at part load. Drives and draught control are often among the quickest paybacks in the plant.
Fuel per tonne of clinker
Excess air and unstable feed raise fuel use. Flue O₂ and feed data keep the kiln steady.
Textiles
Cost tracked per kilo of fabricAir-jet looms are air-hungry, humidification runs at peak all day, and dyehouses heat more water than they need.
Compressed air for looms
Pressure control and a leak programme save a large share of compressor power.
Humidification and ventilation
Fans and pumps sized for the hottest day run at that speed all year. Drives match them to the weather.
Dyeing heat
Batch-by-batch steam and hot-water use reveals over-heating and heat that could be recovered.
Meat & cold chain
Cost tracked per tonne storedCompressors, condensers and evaporators drift out of tune silently, while defrost timers and open doors add load every hour.
Refrigeration efficiency
Suction and discharge pressures with compressor power show efficiency falling before rooms warm up.
Defrost and doors
Demand-based defrost and door alerts remove load added by fixed timers and open doors.
Temperature records
Product and room temperatures logged automatically for buyers, auditors and regulators.
Plastics & packaging
Cost tracked per kilo producedEvery machine has its own energy per kilo, chillers often run colder than needed, and scrap is energy paid for twice.
Energy per kilo, per machine
Barrel heaters and drives compared machine to machine and shift to shift.
Chillers and cooling
Chilled water colder than the process needs costs every hour. Setpoints matched to the product.
Scrap rate
Scrap tracked by machine, product and cause, so the worst offenders get fixed first.
Don’t see your industry?
If your plant runs motors, steam, compressed air or refrigeration, PlantOS can measure it. Tell us what you make.