Targeted Impact Across Functions That Drive Chemical Plant Performance

Digital transformation is only as valuable as the impact it creates across the entire organization.

Energy & Heat Losses

Tracking and managing energy losses remains a challenge due to hidden inefficiencies and disconnected systems like these:

  • Hard to track pockets of electrical losses

  • Invisible Boiler and steam loss in TPH

  • Data in a siloed SCADA or manual readings

  • Utility handled with the operator's gut feel

Unplanned Downtime

Without proactive systems in place, downtime often strikes unexpectedly - here’s how it shows up on the ground:

  • Reactive or insufficient maintenance

  • Weeks-long downtime slows production

  • Untracked, undocumented repair jobs

  • Reliance on manual handheld checks

Production Gaps

Lack of real-time insights leads to inefficiencies and blind spots across production cycles, such as:

  • No process performance visibility

  • Missed opportunities to improve TAT

  • Delayed root cause until later batches

  • Limited chronological process insight

Safety Blindspots

Critical safety lapses often go unnoticed due to missing logs and delayed responses - here are some real-world examples:

  • Fire-safety systems get tampered with

  • UPS, Battery Systems, or VFDs Catch Fire

  • Audit Logs are not readily available

  • Delayed Inspections and Gas Leaks

Compliance Lags

Inefficient systems and scattered data often stall compliance efforts - manifesting through issues like these:

  • Manual recordkeeping slows reporting

  • Time consumed in finding the material in the plant

  • Teams run amok in gathering ESG reporting data

  • Delayed escalations for inspections and approvals

Solution Stacks

Unlock peak plant performance across energy, reliability, productivity, safety, and compliance for every stage of chemical manufacturing, driving efficiency and measurable results.

Energy Management
Cost savings of electrical, renewable & utility assets
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HVAC Automation
Intelligent Automation of chillers, pumps, and cooling towers
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Water Distribution
Continuous tracking and control of water across ETP, STP, and WTP
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Renewables Optimization
Increase the renewable and WHRS contribution in production
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Boiler Efficiency
Track heat-rate, auxiliary, and steam generation efficiency
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Fuel and DG
Manage DG performance, fuel consumption, and prevent theft..
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Predictive Maintenance
AI-enabled CBM and predictive diagnosis for critical rotating assets
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Power Quality Analyzers
Electrical analytics for active and passive filters and transformers
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Steam Trap Diagnosis
Automated monitoring of steam networks and boiler operations
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Conveyor Health
I/O Vision for Conveyor health and fault identification
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Busbar Health
Online Busbar monitoring and alerts for heating
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IT-OT Integration
Unify siloed plant-floor OT systems and Business IT systems for a unified data fabric
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Process Digital Twin
Live, virtual replicas of production flows and processes for optimization with GenAI
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Golden Batch Analytics
Instantly pinpoint top-quality batches using a unified LIMS and process data
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Digital Logbook
Create digital check sheets, reports, and forms on the fly with Digital Logbook
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Job Automation
Link machine sensor data to ERP for automating repair jobs, tracking asset genealogy, and more
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Batch Traceability
Full digital tracking of every batch across the plant from container to lot to tank
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ESG Reporting
Real-time ESG data availability for automated documentation
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Online Fire Safety
Fast identification of fire safety equipment, alerting for readiness drops
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Vision Safety
I/O Vision for in-plant violations and incident inspection
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AQI Monitoring
Continuous ambient air quality and gas leak surveillance
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Emissions Reporting
Direct, automated submission to government authorities
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Impact Across Department

Targeted Impact Across Functions That Drive Chemical Plant Performance

Digital transformation is only as valuable as the impact it creates across the entire organization.

Productivity Gains
Commercial Gains
Operations & Production
Plant Manager, Operations Manager, Production Manager
Improved process transparency
1.5x faster job allocation
2–3% higher batch yield
20-25% improved TAT.
Utilities & Energy Management
Utility Manager, Energy Manager, Chief Engineer
Smarter energy plant-wide forecasting
20x faster response to utility incidents
Upto 12% of reduction in SEC/SHC
95% reduction in utility wastage
Maintenance & Reliability
Maintenance Manager, Reliability Manager, Maintenance Engineer
Proactive monitoring of all critical assets
1.5x faster preventive maintenance
2-3% higher batch yield
20-25% improved TAT.
Quality & Lab
Quality Manager, QA/QC Manager, Lab Manager
3× faster batch analysis
Instant quality insights for operators
Up to 40% faster quality control cycles
Fewer batch deviations and rework
EHS (Environment, Health & Safety)
EHS Manager, Safety Manager, Environment Manager
Digital safety compliance and instant audits
Faster zonal hazard risk detection
Significantly reduced safety mishaps
90% faster risk response
IT and EnI Teams
IT Managers, EnI Heads, Automation Engineering
Scale across lines, plants in weeks
Self-service plug-and-play connectors
1.5x more resource efficient Infrastructure
High uptime of the platform microservices
PRODUCT ECOSYSTEM
Dashboard Image

How Faclon’s Agile Products Align with Real Plant Operations

Our full-stack platform drives ground-up digital transformation, deploying from field devices to enterprise systems. Each product module works in seamless succession to unify, analyze, and optimize every layer of chemical manufacturing.

I/O Connect
I/O Connect is your industrial data backbone seamlessly unifying machines, sensors, and enterprise systems into a single source of truth for smarter operations
I/O DeepSense
DeepSense is your industrial foresight engine harnessing AI and machine learning to predict failures, optimize performance, and unlock new levels of operational intelligence
I/O Sense
I/O Sense is your operational intelligence layer transforming industrial data into real-time dashboards, workflows, and actions for smarter, faster decisions
Bruce AI
Bruce AI is your industrial copilot delivering contextual intelligence, clear explanations, and decisive actions that transform complexity into clarity.

Serving the Entire Spectrum of Chemical Manufacturing

The chemical industry is the backbone for many sectors, from pharma to infrastructure, with three major bifurcations

Basic Chemicals

The bulk production of foundational chemicals includes the manufacturing of raw materials for other
High energy and utility needs
The largest emission exposure
Heavy Industrial operations
Critical O&M needs

Intermediate Chemicals

Production of dyes, solvents, and chemical building blocks for downstream industries.
Batch operations with precise quality requirements
Strict traceability for inputs and outputs
Moderate emissions & effluent concerns
Frequent product changeovers

Specialty Chemicals

High-value, customized formulations for pharma, agro, coatings, and personal care.
Small batch, high-complexity production
Stringent GMP and regulatory standards
Focus on quality assurance
Sensitive to contamination

Your Partners in Industrial Transformation

Discover how Faclon delivers measurable value to every role from strategy to operations, maintenance, and the shop floor.
Rajveer Singh
Solution Expert

Expert in applying vision analytics to measure particle size, monitor conveyors, detect quality defects, and ensure safety compliance — enabling smarter operations with reliable, real-time visual intelligence.

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Hitesh Choudhary
Solution Expert

Specializes in building digital twin solutions that accurately mirror real-world operations, while enabling end-to-end traceability to improve quality, compliance, efficiency, and transparency across complex industrial processes.

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Kapil Dev
Senior Sales Representative

Specializes in delivering OEE insights for productivity improvement, enabling seamless PLC control for automated processes, and streamlining CMMS workflows to enhance maintenance efficiency and reduce downtime.

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Vivek Jaiswal
Solution Expert

Specializes in managing water systems with digital intelligence, delivering accurate renewable energy forecasting, and providing deep RHT insights to improve efficiency, reliability, and sustainable industrial operations.

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Siddharth Jha
Solution Expert

Expert in creating digital logbooks for seamless data capture, applying statistical process control for quality assurance, and using time series forecasting to optimize planning and operations.

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Vivek Singh
Solution Expert

Focused on delivering predictive analysis to anticipate performance trends, enabling predictive maintenance to minimize downtime, and applying anomaly detection to identify risks before they disrupt operations.

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Parth Chaudhary
Regional Director

Focused on driving energy visibility across plants, improving utilities efficiency with actionable insights, and ensuring reliable operations through advanced bus bar monitoring and performance tracking.

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Archit Naraniwal
Regional Director

Expert in optimizing machine health with predictive insights, bridging IT-OT systems for seamless operations, and forecasting energy demand to ensure efficiency, reliability, and smarter decision-making at scale.

Book a Demo
Parag Patil
Regional Director

Expert in optimizing HVAC chillers and standalone units for peak efficiency while enabling advanced solar monitoring to ensure energy reliability, sustainability, and smarter performance across industrial operations.

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TESTIMONIAL

Resources to keep you updated

IoT Predictive Maintenance: 75% Less Downtime, 18% Cost Savings (Uno Minda)

September 11, 2025

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Artificial Intelligence (AI) has ceased to be just a buzzword and has substantially altered various industries across the globe.
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AI-Powered Safety Revolution: Computer Vision Surveillance for Chemical Manufacturing

September 11, 2025

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IoT-powered solution with automated data, real-time dashboards, dynamic SLDs, and alerts enabling smarter reporting, anomaly detection, and efficient energy control
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125% OEE Growth Achievement: Real-time Machine Monitoring in Cable Manufacturing

September 11, 2025

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IoT-powered OEE solution with HMI, PLC integration, energy tracking, and quality monitoring enabled real-time data, accuracy, and production optimization
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Got Questions? We have Answers

Your comprehensive guide to clearing doubts and exploring in depth information about Steam Trap Monitoring
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Income Analytics

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Income Analytics

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Expense Tracking

What Financial Solutions Does Radar Offer?
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