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Month: June 2026

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case study

Intelligent Power Application for Cement Manufacturing Plant

Intelligent Power Application

Intelligent Power Application for Cement Manufacturing Plant

About Customer

A leading cement manufacturing plant in India, operating with high energy-intensive processes and requiring continuous, reliable power supply for uninterrupted production.

Business Challenges

The client faced several business and technical challenges while setting up the facility:

Requirement for an Intelligent Load Management System

Frequent cascaded tripping of turbo generators (TGs)

Improper load shedding strategy leading to plant-wide blackouts

Lack of real-time energy monitoring and control

High downtime and production losses

Limited visibility into power consumption and system health

Increasing penalties from grid due to instability

Softcon’s Proposed Solution

Softcon provided an advanced automation and control solution using Rockwell Automation’s PlantPAx DCS and related technologies. The key elements included:

PlantPAx Distributed Control System with Point IO

Plantwide Device Level Ring (DLR) Network ensuring zero downtime

60-unit FactoryTalk Batch Solution for consistent process control

Redundant HMI, Alarm & Data Servers for system reliability

Redundant Historian Server & Interface Nodes for data security

Redundant OPC Server for seamless third-party integration

ThinManager Server with 25 Clients for centralized, scalable operations

Virtualization on VMware, enabling flexibility and future readiness

Outcome / Key Benefits

Consistent and reliable power supply to the plant

Significant reduction in grid penalty costs

Improved plant stability and operational reliability

Enhanced decision-making with real-time insights

System Highlights

Speed to Market: Engineering and deployment optimized for faster implementation

System Network & Interface: Zero downtime architecture using robust DLR network .

System Network & Interface: High-speed and secure communication across systems

Quality: Reduced process interruptions leading to stable operations

Plant Visibility: Real-time monitoring of load, demand, and energy usage

Decision Making: Centralized SCADA dashboard enabling instant operational insights

System Architecture

Fully integrated PLC–SCADA–Energy Monitoring System

Redundant controllers ensuring high system availability

Secure industrial communication network across plant operations

Load Shedding System

Automated priority-based load shedding

Prevention of total plant blackout

Intelligent response to overload conditions

Real-time tracking of load distribution and consumption

System User Interface

Intuitive SCADA dashboards

Centralized visualization of:

  • Power distribution
  • Load trends
  • Equipment status

User-friendly interface for operators and management

Impact & Business Outcomes

Metric

Improvement

Execution Time

Reduced by 20%

System Downtime

Downtime Reduced by 45% through automation & E&I improvements

Asset Utilization

Improved by 40% with optimized load management

Decision Making

60% faster with real-time visibility

Energy Efficiency

Improved significantly with smart load control

Grid Penalties

Reduced through maximum demand optimization

Conclusion

Softcon successfully transformed the plant’s power management system into a smart, automated, and highly reliable infrastructure.

With advanced load management, real-time monitoring, and intelligent automation, the plant now benefits from:

  • Improved operational stability
  • Reduced downtime and energy losses
  • Enhanced efficiency and cost savings

Neeta Kulkarni

Head Projects

Neeta Kulkarni

HR and CSR Director, Softcon

Neeta Kulkarni is the dedicated HR and CSR Director at Softcon Systems Private Limited. With a strong passion for people and positive change, she plays a key role in building a supportive and inclusive work environment. Her efforts help employees grow, stay motivated, and feel valued.

As a leader in Corporate Social Responsibility (CSR), Neeta also ensures that Softcon contributes meaningfully to society. From community development to employee well-being, she focuses on making a lasting impact both inside and outside the organization.

Her leadership blends care, strategy, and social awareness, helping Softcon grow as a people-first and purpose-driven company.

Sales Director at Softcon - provides VFD/AC/DC Drive Repair Services in Pune,India,

Vinayak Hegde

Director Sales

Vinayak Hegde

Director Sales, Softcon

Vinayak is a seasoned professional with many years of experience in creating strategic roadmaps, driving corporate growth, and delivering impressive results. He has led high-performing teams and managed diverse responsibilities, significantly increasing annual revenues for multinational companies. His innovative approach has helped companies like Siemens and GE double their revenue in record time by breaking into competitive markets.

An expert in IIoT-connected enterprise solutions and product management, Vinayak is a true source of wisdom in automation, people management, and thoughtful leadership. His dedication to quality and continuous improvement consistently propels groundbreaking achievements across various industries, making him a key force in transforming business challenges into growth opportunities.

Service Head in softcon, Best AC/DC drive repairs services in india

Chintamani Unde

Service Head

Chintamani Unde

Service Head, Softcon

Chintamani Unde is a seasoned leader responsible for overseeing the entire maintenance and drives repair department, bringing extensive expertise and unwavering passion to his work.

With a strong background in managing large-scale service teams and optimizing repair processes, he consistently drives operational excellence and innovation. His strategic approach has reduced service downtime, improved customer satisfaction through proactive maintenance strategies, and optimized operational costs without compromising quality.

Chintamani’s commitment to translating vision into action and his ability to lead cross-functional teams ensure that the organization upholds high standards of quality and reliability, making him essential to boosting customer happiness and overall service performance.

Umesh Kulkarni - Project Director, Softcon is best Drive repair services company in pune ,india

Umesh Kurulkar

Project Director

Umesh Kurulkar

Project Director, Softcon

Umesh Kurulkar is the Project Director and the driving force behind our smooth operations. With many years of experience, he has built a team that works together efficiently to reach clear goals.

Umesh is known for his practical approach to solving problems and improving everyday work. He focuses on turning ideas into simple, clear actions that help the company grow and succeed. His strong leadership and dedication to continuous improvement have made the company a leader in the industry.

Umesh’s hands-on style ensures that every part of the business works well, creating a culture of steady progress and success.

Mansing Beloshe

Head Projects

Mansing Beloshe

Head Projects, Softcon

Mansing Beloshe is an experienced Project Manager with a strong background in the industrial automation industry. With expertise in Process Control, Engineering, Control Systems Design, Process Automation, and Project Engineering, he has successfully led numerous projects, driving efficiency and innovation.

His strategic approach to program and project management ensures seamless execution, from planning to implementation. A graduate of Sanjween Vidhyalay, Panchgani, Mansing is committed to delivering high-quality automation solutions that enhance operational performance and reliability.

Chintamani Unde

Service Head

As a Senior Manager for Service & Repair at Softcon Systems Pvt. Ltd., Chintamani Unde contributes knowledge and a commitment to providing outstanding service solutions.

Chintamani is essential to boosting customer happiness and upholding the organization's high standards of quality because of its emphasis on streamlining repair procedures and guaranteeing operational excellence.

Vinayak Hegde

Director Sales

Vinayak Hegde is a seasoned professional with 26 years of experience in creating strategic roadmaps, accelerating corporate growth, and producing significant outcomes. He has effectively led high-achieving teams, handled a variety of activities, and overseen yearly revenues of INR 60 crores. Vinayak has been instrumental in helping Siemens and GE double their revenue in record time by using creative tactics to break into cutthroat sectors.

He is an expert in IIoT, linked enterprise solutions, and product management, and he was awarded the Best Project Award at IIM Bengaluru. He also provides automation knowledge and thought leadership. Vinayak's dedication to quality keeps propelling revolutionary achievement in a variety of sectors.

Chandrakant Kulkarni

Managing Director

Chandrakant Kulkarni

Managing Director, Softcon

Chandrakant Kulkarni holds a degree in Electrical Engineering and Management, which laid the foundation for his technical and entrepreneurial journey. His early roles in small companies helped him develop expertise in operations, marketing, and technology, ultimately paving the way for him to establish his own company within a decade.

Initially specializing in power management and process automation, his venture expanded over 22 years into IoT, motion control, and end-to-end integration. His leadership is driven by a relentless passion for innovation and solving complex challenges, creating significant value for customers and stakeholders.

With a visionary approach, Chandrakant Kulkarni continues to inspire industry transformation, setting new benchmarks in technological advancements and business excellence.