IoTreat® cuts energy by 25% and operators by 75% at Kaynes Technology's Mysuru STP — earning a second project at Chamarajanagar
Proven performance at the 70 KLD Mysuru facility leads to a repeat order, with IoTreat® now expanding to Kaynes' 60 KLD plant at Chamarajanagar.
Kaynes Technology India Ltd., a leading electronics manufacturing and IoT solutions company, operates a 70 KLD Sewage Treatment Plant at its Mysuru facility. Like many manufacturing-sector STPs, the plant ran on manual monitoring and fixed operational schedules — four operators managing aeration, pumping, and sludge handling by hand, with no real-time data to guide decisions. Energy consumption was higher than necessary, and plant performance varied with operator availability and judgment.
Challenge
The Mysuru STP's dependence on manual operations meant process efficiency was inherently inconsistent. Aeration ran on fixed cycles regardless of actual load, resulting in avoidable energy waste. Four full-time operators were needed to keep the plant running — a cost that grew with every shift. Without real-time monitoring or predictive alerts, minor inefficiencies compounded undetected, and there was no mechanism for remote visibility or intervention when issues arose outside working hours.
Solution
ParyAI deployed IoTreat® across the Mysuru STP, automating aeration, pumping, and sludge handling while introducing IoT-based real-time monitoring across critical process points. Load-based aeration control replaced fixed schedules, adjusting dynamically to actual influent conditions. A centralised dashboard gave the operations team live plant visibility and remote control capability. AI-driven anomaly detection and predictive maintenance alerts meant the plant could flag issues before they became failures — reducing the need for constant on-site presence.
Outcome
Energy consumption fell from 110 to 82 kWh per day — a 25% reduction, saving 28 kWh daily through intelligent aeration alone. Operator headcount dropped from 4 to 1, a 75% reduction enabled by automation taking over routine monitoring and control tasks. The energy savings carry a measurable carbon impact: at 0.82 kg COâ‚‚ per kWh, the plant avoids approximately 23 kg of COâ‚‚ every day — around 8.4 tonnes per year, equivalent to planting 380–400 trees annually. Plant performance stabilised, operational costs fell, and Kaynes' ESG reporting
IoTreat® cuts energy by 25% and operators by 75% at Kaynes Technology's Mysuru STP — earning a second project at Chamarajanagar
Proven performance at the 70 KLD Mysuru facility leads to a repeat order, with IoTreat® now expanding to Kaynes' 60 KLD plant at Chamarajanagar.
Kaynes Technology India Ltd., a leading electronics manufacturing and IoT solutions company, operates a 70 KLD Sewage Treatment Plant at its Mysuru facility. Like many manufacturing-sector STPs, the plant ran on manual monitoring and fixed operational schedules — four operators managing aeration, pumping, and sludge handling by hand, with no real-time data to guide decisions. Energy consumption was higher than necessary, and plant performance varied with operator availability and judgment.
Challenge
The Mysuru STP's dependence on manual operations meant process efficiency was inherently inconsistent. Aeration ran on fixed cycles regardless of actual load, resulting in avoidable energy waste. Four full-time operators were needed to keep the plant running — a cost that grew with every shift. Without real-time monitoring or predictive alerts, minor inefficiencies compounded undetected, and there was no mechanism for remote visibility or intervention when issues arose outside working hours.
Solution
ParyAI deployed IoTreat® across the Mysuru STP, automating aeration, pumping, and sludge handling while introducing IoT-based real-time monitoring across critical process points. Load-based aeration control replaced fixed schedules, adjusting dynamically to actual influent conditions. A centralised dashboard gave the operations team live plant visibility and remote control capability. AI-driven anomaly detection and predictive maintenance alerts meant the plant could flag issues before they became failures — reducing the need for constant on-site presence.
Outcome
Energy consumption fell from 110 to 82 kWh per day — a 25% reduction, saving 28 kWh daily through intelligent aeration alone. Operator headcount dropped from 4 to 1, a 75% reduction enabled by automation taking over routine monitoring and control tasks. The energy savings carry a measurable carbon impact: at 0.82 kg COâ‚‚ per kWh, the plant avoids approximately 23 kg of COâ‚‚ every day — around 8.4 tonnes per year, equivalent to planting 380–400 trees annually. Plant performance stabilised, operational costs fell, and Kaynes' ESG reporting