Stop Guessing Your Production Costs
Track Electricity, Water, Air & Manpower in Real-Time to Calculate the True Cost Per Minute of Manufacturing
Most SCADAs show machine status. The Advance Portal shows money. See exactly what each shift, each batch, and each product line costs—down to the minute.
✓ Real-Time Costing | ✓ Energy Management | ✓ IoT Integration | ✓ Cloud Dashboard
The Advance Portal Engine
Most SCADAs only show status—Machine On/Off. We show Money. Every utility consumption is converted into cost, every hour of downtime into lost revenue.
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Production Output
💰 The Game-Changing Benefit: Spot the exact minute your profit margin drops due to an air leak, a voltage spike, or an idling machine. See cost anomalies before they destroy your quarterly targets.
6 Critical Data Streams—One Unified Dashboard
1. Electricity
Smart Energy Meters capture kWh, Power Factor, Maximum Demand. See real-time consumption per machine, per shift, per product line.
2. Water
Flow meters track consumption per batch, per process. Identify leaks, optimize cooling circuits, and reduce wastewater charges.
3. Compressed Air
The most expensive utility in any factory. Flow and pressure monitoring reveals leaks that silently drain 30-40% of generation capacity.
4. Fuel (Oil/Gas)
Flow meters on boilers, heaters, and generators. Calculate fuel cost per unit of steam, per ton of hot water, per batch processed.
5. Raw Material
Weighing scales and load cells integrated for precise material tracking. Know exactly how much you used vs. how much you should have used.
6. Manpower
RFID/Biometric integration tracks labor hours per department, per shift. Calculate true labor cost allocation across production lines.
All Six Streams Feed One Cost Engine
Separate systems create data silos. The Advance Portal unifies energy, utilities, materials, and labor into a single manufacturing cost dashboard. Finally, production and finance speak the same language.
Who Needs This? Industries Where Cost Visibility = Competitive Advantage
🧵 Textile & Dyeing
Where water and steam costs are huge, and batch consistency determines profitability:
- Water Consumption: Track usage per shade, per dye recipe, per machine
- Steam & Thermal Oil: Monitor boiler efficiency and heat losses in real-time
- Electricity Per Batch: Compare energy usage across shifts to identify inefficient operators
- Chemical Dosing: Ensure recipe accuracy and reduce material wastage
- Effluent Charges: Calculate true cost of wastewater treatment per batch
ROI Reality: One textile mill reduced water consumption by 22% in 3 months by identifying process inefficiencies through real-time monitoring.
Get Textile Solution Demo
🔨 Steel & Forging
Where electricity is 30-40% of product cost, and power quality affects yield:
- Furnace Energy Tracking: Monitor kWh per ton melted, per heat cycle
- Power Factor Penalties: Real-time PF monitoring to avoid utility surcharges
- Maximum Demand Control: Load shedding automation to stay within MD limits
- Compressed Air Losses: Air leaks in forging plants waste millions annually
- Shift Efficiency: Compare production output vs. energy input across shifts
ROI Reality: A forging unit saved ₹18 lakhs annually by implementing MD control and fixing compressed air leaks identified by the portal.
Explore Steel/Forging Solution
🍽️ Food & Beverage / Pharma
Where batch consistency, traceability, and cost accuracy determine compliance and profit:
- Batch Costing: Calculate exact cost per batch—utilities, materials, labor, and overhead
- Recipe Deviation Alerts: Detect when actual ingredient usage differs from the recipe
- CIP/SIP Monitoring: Track cleaning cycle costs—water, chemicals, steam, time
- Cold Chain Energy: Monitor refrigeration energy consumption per product stored
- Regulatory Compliance: Automated batch records for audits and traceability
ROI Reality: A beverage plant identified a 15% material over-dosing issue that was costing ₹12 lakhs annually—fixed within one month of portal installation.
Request F&B/Pharma Demo
Download the Factory Utility Cost Audit Checklist
Are you paying for air leaks, poor power factor, or idle shifts without knowing it? Hidden utility costs can account for 5-15% of your total production cost. Use our comprehensive checklist to find the leaks in your P&L statement that nobody talks about in production meetings.
Your FREE Cost Audit Checklist Includes:
- Electricity Cost Analysis (Power Factor, MD Penalties, Idle Load)
- Compressed Air Leak Detection Methodology
- Water & Steam Consumption Benchmarking
- Shift Efficiency Comparison Framework
- Hidden Cost Identification (Startup Losses, Quality Rejections)
- ROI Calculator for Energy Management System Implementation
No registration required. Instant PDF download. Used by 300+ manufacturing CFOs.
Ready to See Your Real Manufacturing Costs?
Schedule a live demo of the Advance Portal. We'll show you how textile mills, steel plants, and food factories are using real-time cost visibility to improve margins by 3-8%. Bring your questions—we'll answer them with data.
Schedule Live Demo 📞 Call Now: +91-8427001018Trusted by: Textile Mills | Steel & Forging | Food & Beverage | Chemical | Pharma | Automotive Components