Ingenio Sancarlos
How we built PLASMA on top of Basis Network to take a sugar mill in Colombia's Valle del Cauca region to a 91% operational efficiency lift and over COP $300M in verified savings in the first 6 months of operation.
Maintenance ran on spreadsheets and operator memory.
Like any industrial-scale sugar mill, Sancarlos runs heavy machinery in continuous harvest cycles: mills, boilers, evaporators, centrifuges. When a critical piece of equipment fails, the whole line stops — and every hour of downtime costs millions of pesos.
Before PLASMA, the mill's maintenance management relied on scattered spreadsheets, paper logbooks, and the memory of veteran operators. There was no real trace of when the last intervention was performed on each piece of equipment, what part was replaced, or what the actual degradation curve looked like.
The result: reactive maintenance, frequent unplanned shutdowns, parts bought at urgency premiums, and a silent loss of operational efficiency that no one could quantify with precision.
An industrial CMMS with predictive AI and immutable on-chain records.
PLASMA is a computerized maintenance management system (CMMS) built on Basis Network. It captures every intervention, predicts failures before they happen, and leaves auditable records that no operator or administrator can alter after the fact.
Predictive maintenance via AI
Machine-learning models trained on the mill's historical data. PLASMA learns the degradation curve of each piece of equipment and raises alerts before a part fails — not after.
Immutable records on Basis Network
Every maintenance intervention is cryptographically signed and recorded on a private subnet on Basis Network. Traceability is real, auditable, and independent of the software — records outlive the system itself.
Built for the factory floor
UI an operator can use with gloves and a hard hat — not an office dashboard. Mobile, tablet, industrial terminal. Offline operation with sync on reconnect.
The numbers that matter, after the first 6 months in production.
operational-efficiency lift, measured on the mill's internal KPIs (mean time between failures, maintenance plan compliance rate, reduction in unplanned shutdowns).
COP in direct verified savings in the first 6 months of operation, counted as: lower emergency parts procurement, fewer labor hours lost to unplanned downtime, and higher aggregate throughput on the production line.
traceability across every maintenance intervention, signed and verifiable, with no possibility of after-the-fact alteration. Internal audits now take hours, not weeks.
“Before PLASMA, maintenance ran on spreadsheets and the memory of our veteran operators. Today we know when each critical piece of equipment is going to fail before it fails — and why. That changed how we run the whole mill.”
The technical decisions behind PLASMA.
Does your industrial operation have a similar problem?
If your company is losing money to reactive maintenance, unplanned downtime, or lack of traceability on critical equipment — book a free 30-minute call and let's talk.