Contents
- Introduction to Digital Intelligence Solution
- Core Digital Intelligence Modules
- Key Equipment & Project Showcase
- FAQ
1. Introduction to Digital Intelligence Solution-IoT-Driven Transformation for Feed Production Management
Traditional feed mills rely on limited data from control rooms, lacking deep analytics. Manual inspections detect visible faults (e.g., material leaks) but fail to monitor equipment 24/7 or analyze trends.
1.1 IoT System Advantages:
(1)Smart Equipment Management:
Predictive maintenance reduces unplanned downtime by 42%, cuts O&M costs by 35%, and extends equipment lifespan by 15%.
(2)Optimized Production Efficiency:
Dynamic adjustment of parameters (e.g., grinding size, pelletizing temperature) increases product qualification rate to 99.6% and reduces energy consumption by 8.7% per ton.
(3)Precise Energy Control:
Peak/off-peak electricity visualization and smart scheduling save 870,000 kWh/year, reduce steam consumption by 13%, and deliver annual energy savings of ¥1.6 million.
1.2 Features:
² Real-time multi-terminal monitoring (phone/PC/TV) for data reports, energy curves, and alerts (e.g., motor overload, bearing temperature).
² Automated generation of equipment utilization, production analysis, and standardized reports (99.98% data accuracy).
² Edge-to-cloud architecture with millisecond-level data collection via industrial IoT gateways.
1.3 Key Modules:
Ø Current, temperature, and vibration sensors for fault prevention (e.g., motor short circuits).
Ø Cooling system monitoring to prevent condensation-induced spoilage.
Ø Visual recognition for non-communicative meters (e.g., moisture detection).
2. Core Digital Intelligence Modules
Host Equipment IoT System:Energy efficiency management, real-time status monitoring, anomaly alerts, and production analysis.
Energy Management A
Energy Management B
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Daily energy consumption distribution analysis
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The daily energy consumption of each equipment is automatically read and calculated
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Equipment efficiency management
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Real-time monitoring of the power-on status of the device
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Get real-time visibility into the monthly uptime rate of each device
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Device status management
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The 24-hour graph makes it easy to see the status of the device. At the same time, there is also historical data, which can be the historical data of the previous month and the historical data of the previous year.
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Stand-alone graph, which can reflect: 1. Time and efficiency of switching formulas; 2. Whether the host is idling; 3. Whether there is equipment idle; 4. Whether it is inefficient to start; 5. Compare the production efficiency of the host
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Equipment anomaly Management
It can monitor the motor of the equipment to prevent the motor from burning out due to short circuit between turns When the current of the section is high or idling for more than a certain time, the site will issue an early warning, and when the site is not processed, the early warning will enter the abnormal report.
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On-site warning
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Capacity reports
Including the report of power consumption per ton of host equipment or production line, including the hourly output of host equipment or production line, etc., including the steam consumption per ton of host equipment or production line, etc
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Pulverizer control module
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Cooler temperature differential control module
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Radar real-time material meter module
The depth of materials in silos, raw material bulk silos, finished product bulk silos, batching silos, crushing silos, and finished product silos is collected
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Communication module
for steam, air compressor, water, flow bulk scales, oil scales, etc. (optional)There is a communication module for steam, air pressure, water, flow bulk scale, oil scale, and weighbridge, which can be collected automatically
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Visual recognition module of the instrument. On-line moisture detection module
Some instruments cannot be collected by communication, but can be collected by vision Detection of cooling moisture and finished product moisture
3. Application Cases
Case 1:Reduced idle time from 360 hours (May) to 85 hours/month, saving $1,857/month in electricity (based on exchange rate: 1 USD ≈ 7 CNY).
Case 2:Cut auxiliary equipment runtime by 50%, avoiding energy waste.
Case 3:Reduced unplanned downtime from 30 to 2-3 hours/month via predictive maintenance.
Benefits: Before using the module, a feed mill in Putian had an unplanned shutdown of about 30 hours per month, and now the unplanned downtime per month is about 2-3 hours The app for preventive maintenance will have a QR code on site, and the mechanic needs to scan it every day for preventive maintenance
Case 4:Improved pelletizer and extruder efficiency by 4%, saving $1,428+/month in costs.
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- Host real-time parameters, load rate
- Health of auxiliary equipment
- OEE
- Real-time underload warning
- the number of shutdwons analysis
- Time of the variety conversion
- Production Output,Tonne of power
- Consumption Report
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Case 5:Benefits: Batch 2 of the mixer, through the efforts of the organization, from 9P/H to 10P/H, the organizational efficiency has been improved a lot.
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- Improve personnel team efficiency
- Batch of the mixer
- Comparison of teams
- Startup Curve Comparison
- Chart
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Case 6:Shifted 15% peak electricity usage to off-peak hours, saving $428/month in electricity fees.
3.Project installation site
4.FAQ
Q1: What does the system do?
A: Digitizes equipment operations for data-driven production optimization, energy savings, and efficiency.
Q2: Compatibility with existing equipment?
A: Non-invasive installation via sensors and software; no hardware modifications required.
Q3: Delivery timeline?
A: 45–60 days, depending on project scale.
Q4: Installation process?
A: Modular hardware; requires basic electrical skills.
Q5: After-sales service?
A: Lifetime support with 3 years free service; minimal annual fees thereafter.
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