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Water and fuel consumption control at a sugar factory Central America

The largest sugar factory in Central America uses Galileosky Base Block Lite tracking units to monitor water and fuel consumption in real time. By receiving operation data from stationary and mobile equipment, the sugar factory optimized operational work and significantly reduced the cost of water, fuel and fleet maintenance.

Intecomsa, Galileosky integrator in Guatemala, proposed the following solution: to equip all the machinery with Base Block Lite.

About the project 

The Guatemala sugar factory faced with the problem of inaccurate water and fuel consumption record keeping. To irrigate fields, the factory uses not only stationary, but also mobile systems that run on diesel engines. The factory did not receive water and fuel consumption data on a regular basis and relied only on data from flow meters. Moreover, there was no confidence in the overall representation as data from factory irrigation systems was not often included in the report.

Challenges

  • Control the water volume in the irrigation systems;
  • Fuel consumption control on mobile equipment.
  • Time and operation parameters control of the machinery.

Solution

First of all, Intecomsa connected a digital magnetic flow meter and a DFM fuel flow meter via MODBUS to Galileosky Base Block Lite. Additionally, pressure sensors were connected on the irrigation line and engine speed control.

Thus, the tracking unit operates power supply of the fuel flow meter and magnetic flux, preserving irrigation system battery charge during stops. Besides, Intecomsa implemented additional equipment, which is also connected to the unit to monitor and measure pressure on irrigation nozzles.

Together with the customer, Intecomsa developed an online platform to display water and fuel consumption and analyze their cost. Apart from this information, the unit transmits the location and operating time of the equipment.

Gonzalo Galindo, CEO of Intecomsa:

- Galileosky devices were recommended by the manufacturer of fuel level sensors. We opted for Galileosky Base Block Lite for its versatility, the amount of inputs and ability to process data before sending via Easy Logic. We made sure that Galileosky is not just a transmitter and data storage unit, but the device for real control.

Result

Factory sees status data of all irrigation installations on different plantations in real time and always knows if equipment works on scheduled days and hours. In terms of engine speed and pressure in the irrigation system, the factory optimizes technical equipment usage and does not overload and damage it, as it used to be. Moreover, there is a significant fuel economy because the factory knows how much engines consume and how much fuel is burned during working time.

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