Carborundum Universal Ltd
Carborundum Universal Ltd (CUMI), Kochi, is a leading manufacturer in the abrasives and ceramics sector. Operating advanced furnaces for production, the company requires precise temperature monitoring to ensure consistent product quality, efficiency, and safety in its operations.
At a glance
By deploying Babble Lite, CUMI operators gained real-time furnace visibility, reduced downtime, and leveraged in-built reporting with customizable dashboards enabling safe, efficient, and remote monitoring.
Challenges
They required a cost-effective, web-based, and scalable solution to address these gaps.
CUMI Kochi’s legacy SCADA system created multiple hurdles:
No vendor support or upgrades.
Limited remote access and monitoring.
No inbuilt alerts for temperature overshoot.
Lack of historical reporting for efficiency analysis.
Need for customized dashboards to virtually view furnaces.
Solutions
To meet CUMI’s requirements, we deployed Babble Lite with the following features:
Seamless Integration: Connected to the existing Siemens SCADA database via custom plugins.
Real-Time Monitoring: Web-based interface for continuous furnace temperature tracking.
Custom Dashboards: Virtual furnace visualization tailored for operators.
Smart Alerts: Built-in alarms for temperature overshoot and critical events.
Historical Reporting: Tools for analyzing efficiency and long-term performance.
Training & Support: End-to-end training with dedicated, cost- effective support.
40%
Downtime reduction
<5 min
Avg. response time to alerts
30%
Improvement in efficiency
70%
CTime saved in reporting
Results
Automated QR code reading under tough conditions.
Downtime Reduction
Operators could proactively monitor and respond to temperature variations reducing unplanned downtime.
Efficiency Improvement
Historical reporting enabled analysis of process efficiency, leading to improved furnace operations.
Operator-Friendly System
Intuitive dashboards made the system easy to adopt and use daily.
Cost Savings
Eliminated the high licensing and maintenance costs of traditional SCADA solutions.
Reliability & Stability
No complaints or technical issues reported since deployment, reinforcing Babble Lite’s robustness.
“Babble Lite proved to be a robust, cost-effective solution. The stability and ease of use have been impressive, and it fit perfectly within our budget. Our operators quickly adapted to the system, and the visibility we gained has made a significant difference. ”
Conclusion
By adopting Babble Lite, CUMI Kochi successfully transitioned from a legacy SCADA system to a modern, web-based furnace monitoring solution. The deployment enhanced operational visibility, reduced downtime, and empowered operators with intuitive dashboards and actionable insights.
