Successful project · Chemicals
Plant One – a chemical plant run from one live portal
Our team digitalised and helps run a chemical plant – stock, production, quality, stores, logistics and dispatch, up to on-time, safe delivery to the client.
10stages on one live thread
Everybatch released by the lab
GPSon every hazardous truck
OTIFtracked for every order
What the team delivered
✓ Live tank stock with reorder alerts
✓ Reactor plans, batch records, lab release
✓ Safe, tracked hazmat delivery
The whole plant as a live 3D modelDrag to turn · click a stage
🖱 Drag to rotate · click a stage
From customer order to delivery – one unbroken threadDots show the order moving · AI watches every stage
Tank farm and stores – live stock with reorder alertsExample values · levels from tank sensors
T-01Methanol72%
T-02Acetone58%
T-03Toluene31%
T-04Sulphuric acid84%
T-05Caustic lye46%
T-06Finished product65%
🧠 All tanks above reorder level
| Store item | Stock | Cover |
|---|---|---|
| HDPE drums 200 L | 1,240 | 18 days |
| IBC 1000 L | 86 | 6 days |
| Catalyst C-12 | 140 kg | 22 days |
| Hazard labels | 3,500 | 30 days |
| Nitrogen cylinders | 12 | 2 days |
Production plan – every reactor, every batch, against the due dateExample plan · the line shows the time now
MonTueWedThuFriSat
R-101
B-2417 · Resin ACIPB-2421 · Resin BB-2426 · Resin A
R-102
B-2418 · Solvent blendCIPB-2422 · due Thu ⚠B-2427
R-103
B-2419 · Esteridle – pull batch aheadB-2424 · Ester
R-104
B-2420 · Acid washCIPB-2425 · Acid wash
Packing
B-2417B-2418B-2419B-2421
🧠 B-2422 may miss its due date – move to R-103 (idle Wed)🧾 3 customer orders linked to this week's batches🛢️ Raw material reserved for every planned batch
Quality – every batch tested, trended and released by the labExample values · viscosity by batch
✅ Batch released
Batch B-2417 · lab tests
AppearanceClear liquid✓
pH6.8✓
Viscosity51.2 cP✓
Purity99.4 %✓
Moisture0.08 %✓
CoAQ-5531 issued✓
Hazardous chemicals delivered safely – tracked to the client's gateIllustration · live GPS and sensor feed
🚚 Tanker TK-07 · on route
8Sulphuric acid 98% · UN 1830 · Class 8 corrosive
46km/h · limit 50
1 h 52 mETA to client
31.4°tank °C
Sealedseal no. 77412
- ✅ Gate-out safety check passed
- ✅ CP-1 weighbridge – weight matches invoice
Plant One🏠 Dashboard🛢️ Inventory📅 Planning⚗️ Production🧪 Quality📦 Stores🚚 Dispatch
97%On time in full
6Batches running
18 dStock cover
2AI alerts
AI agents · alerts
🛢️Toluene tank T-03 near reorder level – purchase raised
🧪Batch B-2422 viscosity trending high – lab alerted
Deliveries this week
Stage details
★ Key features
🛢️Live tank levels🔔Reorder alerts📅Reactor scheduling📝Electronic batch record🔌DCS, PLC & IoT connect🧪QC tests & CoA🔗Batch traceability📦Storage by hazard class🪪Vehicle & driver checks📄TREM card & SDS☣️Gate-out safety checklist🛰️Live GPS & geo-fence⏱️ETA to the client✍️Proof of delivery🎯OTIF dashboard📲WhatsApp + email alerts
● Example AI alerts
🛢️ Toluene tank T-03 below reorder level – purchase raised🧪 Batch B-2422 viscosity near upper limit – lab alerted⚗️ Reactor R-102 temperature above recipe – shift in-charge alerted☣️ Tanker TK-07 held at gate – earthing check pending🚚 TK-04 halted 25 min off plan – transporter called✅ Order SO-1182 delivered on time – proof of delivery received📅 R-103 idle on Wednesday – batch pulled ahead📦 Acid and alkali drums in the same bay – moved
Key features
Everything a chemical plant needs – in one portal
🛢️Live tank levelsfrom level sensors🔔Reorder alertspurchase raised in time📅Reactor schedulingby due date and recipe📝Electronic batch recordno paper log sheets🔌DCS, PLC & IoT connectplant data read live🧪QC tests & CoArelease only after pass🔗Batch traceabilitylot to drum to customer📦Storage by hazard classmismatches flagged
🪪Vehicle & driver checksfitness, permits, licence📄TREM card & SDSprinted with every load☣️Gate-out safety checklistbarrier opens when green🛰️Live GPS & geo-fencespeed and slow zones⏱️ETA to the clientshared automatically✍️Proof of deliveryphoto, time, signature🎯OTIF dashboardper customer and transporter📲WhatsApp + email alertswith escalation
Order to delivery
From customer order to the client's gate – one unbroken thread
The order moves through ten stages. AI agents check stock, recipe limits, lab results, permits, speed and arrival time at every step.
Stage by stage
Ten stages, one live thread – and what AI watches in each
Every order carries its own record through the plant: which raw material lot, which reactor, which lab result, which drum, which truck.
🧾1 · Sales orderQuantity, grade and promised date captured – the on-time clock starts.AI: promise only what stock and reactors allow
🛢️2 · Raw material & inventoryLive tank and drum stock, goods receipts and reorder levels.AI: low, slow-moving and expiring stock
📅3 · Production planningBatches placed on reactors by due date, recipe and cleaning time.AI: clashes, idle reactors, late batches
⚗️4 · ProductionElectronic batch record with temperature, pressure and time from the plant.AI: readings outside recipe limits
🧪5 · Quality labSamples, tests and certificate of analysis – release only after pass.AI: results drifting towards a limit
📦6 · Stores & packingDrums, IBCs and tankers filled, labelled and batch-coded.AI: incompatible chemicals stored together
🗺️7 · Logistics planningVehicle, transporter, route, permit and loading slot for each order.AI: expired fitness, permit or licence
☣️8 · Dispatch safetyGate-out checklist: placards, TREM card, SDS, earthing, seals, weight.AI: gate stays shut until all checks pass
🚚9 · Last-mile deliveryLive GPS, speed, halts and ETA shared with the client.AI: over-speed, deviation, long halts
✅10 · Delivered on timeProof of delivery with photo and signature closes the order.AI: OTIF score per customer and transporter
Safe delivery of hazardous chemicals
No truck leaves the gate until every safety check is green
The dispatch team ticks each check on a phone at the gate. The barrier stays down until all of them pass – then the truck is tracked until the client signs.
🔥Flammable
🧪Corrosive
☠️Toxic
❗Harmful
🐟Environment
⭕Oxidiser
- Products stored and loaded by hazard class – mismatches flagged
- Safety data sheet (SDS) and TREM card printed with every load
- Every route risk-checked first with a JRM journey risk profile
- Live GPS with speed limit, slow zones and night-driving rules
- Route deviation or long halt alerts the transporter and plant at once
- Emergency numbers along the route, ready on the driver's phone
- Proof of delivery with photo, time and signature closes the order
Traceability
Trace any drum back to its raw material – in one click
If a customer reports a problem, the plant sees the whole chain at once, forwards or backwards.
How the team delivered it
From paper registers to a live, connected plant
Study
Walked every stage with the plant team – orders, tanks, reactors, lab, stores and gate.
Design
Screens, batch records, safety checklists and alert rules agreed before building.
Connect
Tank sensors, plant data, weighbridge, lab results and truck GPS brought into one portal.
Run
Training, go-live and ongoing support – the team keeps improving it with the plant.
- Management sees stock, batches, quality and deliveries on one screen
- Orders promised only when stock and reactor time are really available
- Every hazardous load tracked from gate-out to the client's signature
3D illustration
Run a chemical or process plant?
We will show you how Plant One can be customised for your products, tanks, reactors and customers.