Executive Summary
In 2022, Koidra partnered with Ayo Biomass to optimize operations through an advanced, data-driven approach. Ayo Biomass faced challenges related to managing diverse feedstock moisture levels, particle sizes, and operational inefficiencies. Through a two-phase approach using Koidra’s DataPilot and KoPilot, Ayo Biomass was able to streamline decision-making and enhance both production and energy efficiency across the plant.
Customer Overview
Ayo Biomass a leading wood pellet producer based in Vietnam, has been supplying sustainably sourced wood pellets to the Asian green energy market since 2017. By 2023, Ayo Biomass sought to remain competitive by optimizing its production processes, improving resource utilization, and reducing operational costs. Koidra’s solutions, DataPilot and KoPilot, were selected to enhance data insights and optimize key operational areas throughout the plant.
Ayo Biomass’s Plant 1 has already had a Drying line. Working with Koidra, Ayo Biomass has 2 requests:
- Improve the performance of their existing Drying line
- Provide a complete automation solution for their new Drying line
Challenges and Solutions
Ayo Biomass faced two main challenges:
- Data Collection and Insights: The company needed more robust, centralized data collection and analysis capabilities. While basic production metrics were available, Ayo Biomass lacked the ability to record, analyze, and act on historical data, limiting its ability to optimize operations in real-time and over time.
- Production and Energy Optimization: Ayo Biomass required a solution to optimize production throughput and energy consumption while minimizing manual intervention. Their existing systems were inefficient and lacked the flexibility necessary to adjust dynamically to changing operational conditions. Koidra’s KoPilot was introduced to optimize these processes by providing real-time control and transparency into operational decisions.
Phase 1: Implement DataPilot for Data Collection, Monitoring, and Remote Management
Challenge
Before DataPilot, Ayo Biomass struggled to effectively collect, analyze, and utilize operational data for production optimization. Although basic metrics like feedstock moisture levels, pelletizing capacity, and energy consumption were available, the company lacked the ability to record and analyze historical data or remotely access insights. This limited their ability to track performance trends over time, respond quickly to operational issues, and make data-driven decisions.
Solution
Koidra implemented DataPilot, a platform designed specifically to address the operational needs of manufacturing companies. By centralizing and streamlining data collection across the entire plant, DataPilot enabled Ayo Biomass to go beyond basic metrics and achieve deeper insights through historical data analysis, real-time monitoring, and remote access.
- Agility in Data Analysis: DataPilot enabled rapid data analysis, eliminating bottlenecks by removing the need for IT or database administrators. This agility allowed shop-floor personnel and managers to quickly respond to emerging trends, identify inefficiencies, and make informed decisions that enhanced operational performance.
- Remote Monitoring and Historical Data: DataPilot allowed Ayo’s team to remotely monitor plant operations and access historical data. This capability enabled the team to reorganize data for trend analysis and optimize decision-making over time. With the ability to monitor performance from any location, Ayo Biomass could identify issues faster and implement corrective actions, leading to improved oversight and operational efficiency.
- Smart Alarms: The platform also introduced AI-driven intelligent alerts, designed to minimize false positives and ensure that only critical issues were flagged. This rule-based and AI-driven system helped reduce disruptions while maintaining confidence in automated processes.
Phase 2: Enhance Automation Across the Plant with KoPilot
Challenge
Building on the success of Phase 1, Ayo Biomass aimed to further optimize key areas of plant operations, including production throughput, energy consumption, and resource utilization. The existing systems required excessive manual intervention and lacked the flexibility needed to optimize overall performance. The challenge was to implement a solution that enhanced operational efficiency while making the system transparent and manageable for the operations team.
Solution
Koidra introduced KoPilot, a decision-support platform designed to optimize production and energy use. KoPilot was implemented to enhance operational efficiency by integrating real-time data insights from DataPilot with advanced control strategies.
- Production Optimization: KoPilot enables automated decision-making by continuously analyzing real-time data and automating adjustments, leading to higher production efficiency and more consistent yields.
- Energy Optimization: A major goal of implementing KoPilot was to reduce energy consumption during the drying and pelleting processes. The platform provided insights into energy use patterns, identifying areas where fuel and electricity could be used more efficiently.
- Operational Transparency: KoPilot simplifies complex plant processes by translating what was previously embedded in sophisticated PLC logic into understandable formulas and rules. This gives operations managers clear visibility into how decisions are made, empowering them to monitor and adjust processes as needed without relying on specialized programming knowledge.
By focusing on production and energy optimization, KoPilot empowered Ayo Biomass to reduce operational costs, minimize resource waste, and improve plant performance overall. This approach allowed the operations team to shift their focus from routine manual interventions to continuous process improvement.
Customer Testimonials
“Koidra’s DataPilot and KoPilot have made a big difference in how we run things. The real-time data and automation tools give us everything we need to keep improving our processes and production, all in one place. It’s helped us make quicker, smarter decisions and stay on top of things more easily.”
— Trang Do, Continuous Improvement Manager, Ayo Biomass
About Koidra Inc.
Koidra is a pioneer in intelligent automation, specializing in solutions for climate tech, green energy, and industrial automation. By leveraging machine learning, IoT, and advanced physics-based algorithms, Koidra’s platforms drive efficiency and sustainability in industries such as biomass energy and greenhouse horticulture.
Our DataPilot and KoPilot platforms empower businesses to harness the full potential of their data, enabling smarter decision-making and streamlined automation..
