Prashant Verma, Co-Founder and Country Head at Nanoprecise Sci Corp, talks about how AI & IoT works to empower the stakeholders of the cement industry

Tell us about the concept of Nanoprecise asset maintenance systems and products.

Nanoprecise is an AI & IoT-based predictive and prescriptive maintenance solutions provider that specializes in the implementation of Artificial Intelligence and IIoT technology for predictive asset maintenance and reducing the carbon footprint of manufacturing plants. The integrated AI-based solution consists of a unique 6-in-1 IIoT sensor and an AI-based automated analytics platform.

The wireless sensor offers real-time insights into the health and performance of industrial assets, by measuring 6 important parameters of vibration, acoustic, speed, magnetic flux, temperature, and humidity. It works on Cellular networks (3G/4G/5G) using an e-sim to connect the machines to the internet. MachineDoctor is Atex and IECEx Zone 0 certified, enabling it to be used within explosive atmospheres/hazardous industrial environments, thereby bringing productivity and safety benefits to manufacturing operations. It also complies with international standards such as C1D2, IP68, FCC/ISED/CE/UKCA & RED. They are truly wireless, which also helps to avoid the hassles of complex wiring. It offers extensive coverage and provides a high level of security for communication.

The AI-based energy efficiency and health analytics platform analyses complex machine health data using a combination of Artificial Intelligence as well as physics-based models to enhance the life of machines. It helps users to track the performance as well as the energy consumption patterns of motor-driven equipment sets, to prevent unplanned downtime and reduce the carbon footprint. It detects patterns automatically by building a prediction model that identifies when a given piece of equipment and its components are approaching the end of their remaining useful lives (RULs) or risk of failure.

The solution also helps to determine which assets are consuming higher energy and can help maintenance teams to mitigate any inefficiencies in their energy consumption. It not only allows them to reduce the carbon footprint but also enables to save energy costs for businesses, thereby allowing them to achieve their Net-Zero Goals. 

The Predictive maintenance framework of Nanoprecise brings the sensor data from over from the site to the corporate network, to help maximize the value of information. It allows maintenance teams to monitor every aspect of the manufacturing operation, leading to greater productivity and reduced emissions. It also helps improve the safety of the operators and operations, with real-time data and predicting issues arising from equipment anomalies/faults. In complicated manufacturing operations, this solution can efficiently monitor the health of critical assets, thereby enabling better operational oversight.


Which machines and equipment of the cement plants can your system monitor?

At Nanoprecise Sci Corp, our unwavering commitment to optimizing and streamlining processes is reflected in our holistic approach to equipment maintenance. With our keen focus on delivering exceptional solutions, we consider each piece of equipment as a separate entity, ensuring that every aspect of the production process is meticulously monitored and maintained. We provide end-to-end automated solutions that cater to the unique needs of cement manufacturers, specifically targeting the health and performance of rotating machines such as mills and roller presses. Our comprehensive approach extends beyond these processes, as we cover a wide range of equipment in the clinker process, including crushers, silos, bucket elevators, vertical roll mills, fans, motors, and kilns, amongst others. The culmination of these efforts represents our unwavering dedication to providing unparalleled solutions that drive sustainable growth and progress.


Do you offer customization in your system solutions?

Customers generally have needs & requirements that are unique, and a one-size-fits-all approach may not meet their specific requirements. Our solution can be customized to meet the individual requirements of the customers with a high level of cybersecurity.

Customizations can help to meet the diverse and evolving needs of customers while enhancing the usability of the solution. For example, integrations with a range of vertical & Horizontal stacks such as CMMS or EAM software such as IBM Maximo provides meaningful insights and recommendations to the users on the shop floor. In addition, it can even monitor complicated machines like the roller press due to its ability to monitor low and ultra-low-speed applications with ease. Moreover, the system can also be deployed on cloud or on-premises servers, thereby allowing for a simple plug & play, hassle-free deployment, without worrying about any extra IT infrastructure.


What is the skill set required for those who are operating your sensors and systems?

Our automated solutions cater to a diverse range of end users, who may possess varying levels of technical expertise, regardless of their department within the cement plant. The system generates real-time alerts that prompt the user to take necessary action, ensuring smooth and efficient operations. In addition, our state-of-the-art dashboard or visualization layer enables end-user monitoring experts to view data from multiple dimensions, delivering an intuitive and user-friendly interface. The seamless integration of these features enables streamlined and optimized operations within the cement plant.


How does data help you better your product?

Cement plants generate a large amount of data that can be leveraged for better operational performance. However, simply collecting data is not enough; it must be analyzed and acted upon to deliver value.

We use AI + Physics based models to analyze these vast amounts of data and offer insights about the performance of machines & equipment sets. The accuracy of our models is an important factor that allows us to offer meaningful insights to our customers. With more data, the models can better capture the underlying patterns and relationships in the data, resulting in improved accuracy. However, it is important to note that simply having more data is not always sufficient; it must also be of high quality and relevance to the problem at hand.


Do you provide training to your customers?

Our system boasts a user-friendly interface that can be readily utilized by end users, irrespective of their technical acumen. With its intuitive design, our solution is tailored to cater to a diverse array of departments within the cement plant, streamlining operations and boosting productivity. The system proactively generates alerts that guide the user’s actions, enabling seamless integration of actionable insights into their workflow. Moreover, our cutting-edge dashboard or visualization layer empowers end-user monitoring experts to view data from a myriad of dimensions, providing comprehensive and valuable insights. The culmination of these features represents a seamless and effortless user experience, fostering unparalleled efficiency and simplicity in operations.


Is there any innovation in the pipeline that the cement industry should look forward to?

We have a dedicated R&D department that focuses on developing innovative solutions to address the challenges facing the cement industry. Our team of experts works tirelessly to identify new technologies and processes that can improve efficiency, reduce costs, and enhance the productivity of our customers.

Our team is currently working on identifying ways & means to corelate the process and equipment parameters of the machines, to provide overall operational visibility. In addition, we are continuously working to improve the capabilities of our sensors to improve their operational efficiency.

With continuous commitment and dedication, we are able to stay at the forefront of innovation and deliver cutting-edge solutions that meet the evolving needs of our customers and the industry as a whole. The R&D department is a key part of our commitment to continuous improvement and ensuring that we remain a leader in the industry.


Do you have a specific solution that tracks energy consumption and carbon emission?

We recently launched our flagship product – NrgMonitor to help customers track their energy consumption reduce their emissions. NrgMonitor is an Energy Efficiency & Health Analytics Platform that helps manufacturers track their energy efficiency & carbon footprint, along with condition monitoring of their motor-driven equipment. It determines which assets are consuming higher energy and allows maintenance teams to mitigate any inefficiencies in their energy consumption, Moreover, it helps them pinpoint faults with the potential to cause downtime and identifies when a given equipment is approaching the end of its Remaining Useful Life. It employs a data-driven approach to help operators achieve their Net-Zero goals while preventing unplanned downtime.


How do you envision your future collaborations with the Indian cement industry?

Efficiently mitigating the conventional challenges demands a judicious and pragmatic approach, emphasizing strategic collaborations that synergize the strengths of each of the partners. At Nanoprecise, our unwavering commitment to our customers’ success is reflected in our tireless efforts to elevate their productivity. By eschewing the traditional role of a vendor and instead forging alliances as a strategic partner, we have fostered enhanced visibility of our customers’ operations, driving sustainable growth and progress. Our global reach is amplified by our strategic partnerships with industry-leading enterprises, and we are proud to collaborate with cement manufacturers and OEMs worldwide to bring innovative solutions that can optimize their overall operational efficiency.