In addition to the production and quality gains they realized, RRB’s engineers and operators were quickly trained on the new system. They can easily make adjustments to the system themselves, so there is little need for field support.
All systems send information to the master control room — where hourly MIS (Management Information System) reports are generated, and sent to the central office server. These reports can then be accessed by the executive office and quality control. With InduSoft Web Studio-based solutions running on both boiler systems, the sugarmaking processes and the wastewater system, RRB Sugar Mills can easily evaluate the system’s overall efficiency. In the cogeneration system, improved efficiency reduces the per-unit generating cost. Also, because the system is less volatile, the costly boiler and turbine are less prone to wear.
The system’s hardware modules also continue to perform reliably. Service calls have been substantially reduced, and costly spare parts are rarely needed. There is a spectacular reduction in overall maintenance expenses.
At the end of the day, RRB was able to gain a competitive advantage by automating their operation. Reduced cost and improved productivity, a natural by-product of this sort of high-tech automation, ensures a triumvirate achievement: more plentiful sugar for local consumption and export, an economic benefit to the local population and plentiful, affordable power for the region — a combination that is hard to beat
* The author is a Business Development Manager at InduSoft.