Challenges Products Dashboard ROI Pricing Start Free Pilot →
⚡ POWERCORE Fuel Cost Reduction ~3%
📄 PAPERMAX Throughput Increase ~3%
🌿 PULP AXIS Energy Saved: 14 Lakhs → 2.4%
⚗️ DOSEFLOW Dose Flow Reduction ~5%
📊 ONEVIEW All Systems Nominal
🔥 Steam Pressure 42.3 bar | Variation ~5% → ~2%
💧 O₂ Level 3.1% Optimal
⚡ POWERCORE Fuel Cost Reduction ~3%
📄 PAPERMAX Throughput Increase ~3%
🌿 PULP AXIS Energy Saved: 14 Lakhs → 2.4%
⚗️ DOSEFLOW Dose Flow Reduction ~5%
📊 ONEVIEW All Systems Nominal
🔥 Steam Pressure 42.3 bar | Variation ~5% → ~2%
💧 O₂ Level 3.1% Optimal
AI-Driven Manufacturing Intelligence

Your Plant.
Made Smarter.
Every Second.

PlantMind AI transforms raw plant data into real-time optimization. From boiler combustion to chemical dosing — autonomous AI closes the loop on operational efficiency.

Start Free 3-Month Pilot Explore Products
~3%
OPEX Reduction
3%
Annual Savings Improvement
~3%
Annual Output Gain
PLANTMIND AI POWERCORE Boiler Opt. ~3% Fuel Cost PAPERMAX Paper Machine ~3% Throughput PULP AXIS Stock Prep ~3% Production DOSEFLOW Chemicals ~5% Dose Flow ONEVIEW Dashboard Live Monitoring
Why PlantMind AI

Challenges Indian Paper Mills Face Every Day

Manual operations, reactive decisions, and inefficient resource use silently erode margins. PlantMind AI fixes that.

⚡
25–35% of Total OPEX
High Energy Costs
Energy consumption is the single largest operational expense after raw materials, directly cutting into bottom-line margins.
⚗️
Risk: Inflated Material Costs
Chemical Overuse
Without precise control, plants overdose expensive additives to compensate for process variation, driving up costs unnecessarily.
💥
Result: Production Downtime
Frequent Paper Breaks
Breaks disrupt production rhythm, causing significant downtime, material waste, and recovery energy losses with no warning.
⏱️
Barrier: Reactive Decisions
Delayed Insights
Manual data logging creates lag between events and decisions, preventing the real-time optimization modern plants demand.
🔥
Sources: Coal/Biomass/Pet Coke
Fuel Variability
Inconsistent fuel quality in biomass, coal, and pet coke leads to combustion instability and boiler inefficiencies.
👷
Issue: Inconsistent Quality
Operator Dependency
Process stability relies on individual skill rather than standardized automated controls — quality varies shift to shift.
Our Portfolio

Five AI Modules. One Integrated Platform.

All modules integrate seamlessly with existing DCS/SCADA systems — minimal disruption, maximum value.

🔥
POWERCORE
Boiler & Energy
📄
PAPERMAX
Paper Machine
🌿
PULP AXIS
Stock Prep
⚗️
DOSEFLOW
Chemical Dosing
📊
ONEVIEW
Unified Dashboard
Boiler Optimization

POWERCORE

AI-driven combustion optimization for maximum fuel efficiency across coal, biomass, and pet coke.

  • 01
    Fuel–Air Ratio Optimization
    Real-time adjustment of fuel-to-air mixture based on live combustion analysis, ensuring complete burning and minimal heat loss.
  • 02
    O₂ & Combustion Tuning
    Continuous monitoring and adjustment of oxygen levels across varying fuel qualities to maintain peak efficiency.
  • 03
    Steam Header Stability
    AI-powered pressure and temperature control for consistent steam supply to all downstream processes.
  • 04
    Blowdown Optimization
    Intelligent blowdown control minimizes energy and water losses while maintaining water quality standards.
~3%
Fuel Cost Reduction
~3%
Combustion Efficiency
~3%
Annual Gain
Stable
Steam Control
POWERCORE — BOILER OPTIMIZATION PRESSURE 42.3 bar TEMP 385° Celsius O₂ LEVEL: 3.1% ✓ OPTIMAL AI ANALYSIS → Eff: 87.3% → Air: +2.1% → Opt: OK → CO: 14ppm → Save: ₹450 → Fuel: -3% → Steam: ✓ → Eff: 87.3% → Air: +2.1% → Opt: OK → CO: 14ppm → Save: ₹450 FUEL SAVED TODAY ₹4,820 COMBUSTION EFF. 87.3% MODE AUTO ●
Paper Machine

PAPERMAX

Predictive analytics for maximum throughput and minimum downtime across the paper machine.

  • 01
    Break Prediction
    ML models analyze process parameters to predict paper breaks 15–30 minutes in advance, enabling proactive intervention.
  • 02
    GSM & Moisture Stability
    Automated control of basis weight and moisture to maintain product quality within tight tolerances.
  • 03
    Speed Optimization
    AI-driven speed adjustments based on real-time quality metrics, maximizing production rate without compromising quality.
  • 04
    Dryer Energy Optimization
    Intelligent steam pressure and dryer section control to minimize energy while ensuring proper sheet drying.
~3%
Throughput Gain
~3%
Production Improvement
~3%
Annual Output Gain
Live
Machine Analytics
PAPERMAX — MACHINE ANALYTICS BREAK RISK PREDICTOR — LIVE BREAK THRESHOLD PREDICTED +20 MIN WET END DRYER CALENDAR GSM 75.2 ± 0.3 ✓ MOISTURE 4.8% TARGET: 5% ✓ SPEED 642 m/min OPTIMIZED ↑ BREAK RISK LOW 8% probability
Stock Preparation

PULP AXIS

Intelligent fiber management for reduced energy and material losses in the stock prep area.

  • 01
    Fiber Consistency Control
    Real-time monitoring and adjustment of pulp consistency for optimal fiber distribution and minimal downstream variation.
  • 02
    Refiner Load Optimization
    AI-driven refiner intensity control based on fiber quality requirements, reducing energy while maintaining target freeness.
  • 03
    Reject Reduction
    Intelligent screening optimization to minimize fiber loss, improving overall yield and reducing raw material consumption.
2.4%
Energy Saved
~3%
Production Improvement
~3%
Output Stability
Smart
Fiber Control
PULP AXIS — STOCK PREP PULPER REFINER SCREEN Rej: 2.1% CONSISTENCY 3.2% FREENESS 350 mL REFINER KW 1,240 pH LEVEL 7.2
Chemical Dosing

DOSEFLOW

Precision dosing AI for cost reduction and quality improvement across all wet-end chemistry.

  • 01
    Retention Aid Dosing
    AI-controlled retention aids based on real-time furnish analysis, ensuring optimal fiber retention while minimizing chemical spend.
  • 02
    Chemical Usage Stabilization
    Automated control of all wet-end chemicals — strength additives, sizing agents, biocides — eliminates costly over-dosing.
  • 03
    pH Control
    Precise pH management optimizes chemical effectiveness, improves formation, and enhances paper strength properties.
~5%
Dose Flow Reduction
1–2%
Rejection Reduction
~5%
Chemical Savings
Auto
Dosing Control
DOSEFLOW — CHEMICAL AI RETENTION AID SIZING AGENT pH CONTROL AI CONTROLLER pH: 7.1 ✓ RET: 2.4 L/T SIZE: 1.8 kg/T SAVINGS: ₹2,100/hr MODE: AUTONOMOUS → HEADBOX / WET-END → DOSEFLOW SAVINGS TRACKER Apr May Jun Now ₹18.4L Saved This Year ↑ ~5.0% vs baseline
Unified Dashboard

ONEVIEW

All optimization modules, all plant data, one unified real-time command center for every role in your organization.

  • 01
    Real-Time KPI Monitoring
    Production rate, efficiency, OEE — all tracked live across every module and plant area.
  • 02
    Energy & Throughput Tracking
    Fuel consumption, steam usage, tons per day, machine speed, and uptime all in one view.
  • 03
    Quality Performance
    GSM, moisture, strength properties tracked continuously with alerts on spec drift.
  • 04
    Root Cause & Downtime Visibility
    Breaks, stops, and process anomalies traced to root cause automatically by the AI.
5
Modules Unified
Real-Time
All Data Feeds
Unified
Cross-Module View
24/7
Monitoring
ONEVIEW — LIVE DASHBOARD BOILER 42.3 bar 87% eff ALL OK ✓ PAPERMAX 642 m/m GSM 75.2 NO BREAKS ✓ PULP AXIS 3.2% Consistency OPTIMAL ✓ CHEM 7.1 pH Ret: 2.4 STABLE ✓ OVERALL OEE — 30 DAY TREND 84.2% Apr May Now ALERTS ✓ Boiler OK ✓ PM Speed ⚠ pH drift ✓ Fiber OK • 2 items CUMULATIVE OPTIMIZATION IMPACT — FY 2026 ~3% PowerCore ~5% DoseFlow ~3% PaperMax 2.4% PulpAxis ~3% OVERALL GAIN ↑ annual output at same operating cost
OneView Live

Real-Time Plant Intelligence

Watch your plant's vitals update live. Every metric, every unit, every alert — in one place.

Key Performance Indicators — Live LIVE
84.1%
Overall OEE
↑ +1.3%
312 T
Prod Today
↑ On Target
₹4769
Fuel Saved
↑ Today
0
Breaks Today
↓ 3 Predicted Averted
Energy Consumption Trend
AI Recommendations — Active
🔵DOSEFLOW: pH drifting to 6.9 — adjusting lime dosing automaticallyjust now
⚠️PAPERMAX: Break probability rising — recommend speed reduction to 628 m/minjust now
✅POWERCORE: Increase combustion air by 2.1% — saves est. ₹320/hrjust now
✅POWERCORE: Increase combustion air by 2.1% — saves est. ₹320/hrjust now
⚠️PAPERMAX: Break probability rising — recommend speed reduction to 628 m/min2m ago
🔵DOSEFLOW: pH drifting to 6.9 — adjusting lime dosing automatically5m ago
Unit Status
Boiler Unit 1RUNNING
Steam TurbineMAINT
Paper Machine #1642 m/min
Pulper ARUNNING
Refiner 11,240 kW
Auxiliary Pump 3TRIP
Chemical DosingAUTO
Savings Meter
Annual Output Gain on Track
0.0%
of 3.0% annual gain target
Financial Impact

Real Returns.
Quantified.

Every module delivers measurable optimization impact. Combined, the full PlantMind AI suite drives about 3% annual output gain at the same operating cost.

~3%
POWERCORE
Fuel Cost Reduction
~5%
DOSEFLOW
Dose Flow Reduction
~3%
PAPERMAX
Throughput Increase
~3%
PULP AXIS
Production Improvement
Overall Gain
~3%
Increase in annual output with the same operating cost
SAVINGS BREAKDOWN BY MODULE POWERCORE ~3% Fuel Cost Reduction PAPERMAX ~3% Throughput Increase DOSEFLOW ~5% Dose Flow Reduction PULP AXIS ~3% Production Improvement COMBINED ANNUAL IMPACT ~3% Per Year *Based on industry benchmarks · Results vary by plant size Overall gain: ~3% annual output with constant operating cost Client-ready metrics aligned across all modules
Commercial Model

Flexible Pricing. Zero Risk to Start.

Begin with a 3-month free pilot and pay only when you see results. Scale at your own pace.

Risk-Free
PILOT
₹0
3-Month Free Pilot
  • One selected optimization area
  • Full implementation & support
  • Measurable results guaranteed
  • No obligation to continue
  • Site assessment included
Most Popular
Modular
MODULES
From ₹5L
Per module / year
  • PowerCore — ₹12L/yr
  • PaperMax — ₹10L/yr
  • Pulp Axis — ₹8L/yr
  • DoseFlow — ₹6L/yr
  • OneView — ₹5L/yr
Maximum Value
COMPLETE
₹30L
Full AI Suite / Year
  • All 5 AI modules included
  • 24/7 dedicated support
  • Continuous model updates
  • Dedicated account manager
  • Full operator training
🎧
24/7 Support
All plans
🔄
Model Updates
Continuous
👤
Dedicated Manager
Account & Technical
🎓
Training
Operators & Engineers
🔌
DCS/SCADA Ready
Minimal disruption
Start Today

Transform Your Plant
With AI — Zero Risk.

Start with a 3-month free pilot. Select one area — Boiler or Paper Machine — and see measurable results before committing to anything.

PlantMind AI — Small step for mankind.