PlantOS™ Case Study · Coromandel International
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• Chemicals Fertilizer Manufacturing
• Coromandel Internationa
• Data as of Jan 2026
PLANT RELIABILITY.
Equipment Faults + Process Anomalies
Coromandel International—one of India’s leading fertilizer producers — didn’t just digitize its operations. It closed the loop: from raw sensor signal to prescribed action to user-validated production outcome. Here’s what enterprise-wide reliability transformation looks like across 27 plants.
Read the Full Transformation
Thank you for your interest in
PlantOS™ Prescriptive AI.
Enter your official work email to unlock specs delivering
3 outcomes in 1 prescription — zero guesswork.
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0
Hrs Downtime Eliminated
Unplanned. User-validated.
0
%
Prediction Accuracy Across 48 areas, 266 critical assets
0
Breakdowns AvoidedThrough proactive prescriptions
0
Hrs MTBR550 monitoring locations across 27 plants
All figures validated by Coromandel’s Reliability & Operations teams via PlantOS™ Prescription Engine 
What’s inside
FROM NOISE
TO OUTCOMES.
Mechanical Faults
Vibration, wear & bearing degradation
Physics + AI models detect bearing defects, roller lubrication failure, and mill tripping conditions across Raw Mills, Coal Mills, and Kiln roller assemblies before they cascade into unplanned downtime.
Electrical Faults
Motor overheating & drive anomalies
Temperature trend analysis at motor DE bearings surfaces inadequate lubrication conditions and bearing defect frequencies before they trip Chillers, Evaporators, or Cooling Tower assets.
Process Induced Faults
Parameter drift & production deviation
Continuous 24×7 condition monitoring across Centrifugal and Process Pumps, Scrubbers, and Evaporator Circulation systems detects process shifts before they reach the next stage.
01
550 monitoring points. 27 plants. One Single Source of Truth.
How Coromandel scaled from 32 sensors at Kakinada to 550 monitoring locations across 27 plants — including ATEX-certified sensors for CPC and SSP units — into a single contextualized source of truth.
02
Physics + AI: precision that predictions can’t match
PlantOS™ doesn’t flag anomalies. It traces root cause — across mechanical, electrical, and process domains — with 99.80% accuracy.
03
Diagnostic → Recommendation → Action
801 prescriptions acted upon. 93.47% implementation rate. Real Diagnostic Reports with specific corrective steps — not dashboards, not alerts. Work orders that close.
04
Outcomes the plant’s own engineers signed off on
3,210 hours recovered. 940 breakdowns avoided. MTBR extended to 941 hrs. All figures validated by Coromandel’s own Digital Manufacturing & Operations team.
Prediction
≠
Outcomes.
Most AI deployments stop at the alert. They predict. They visualize. They dashboard. But prediction without a closed loop is just a more expensive alarm bell.
Coromandel’s deployment with PlantOS™ proves the gap isn’t in the model — it’s in the mile between insight and action. The 99% Trust Loop™ is what bridges it. And at enterprise scale — 27 plants, 266 assets, 550 monitoring locations — that mile becomes a mandate.
The 99% Trust Loop™ — how outcomes are guaranteed
1.
Contextualize equipment + process
48 areas, 266 assets, 27 plants — One Prescriptive AI platform
2.
Detect with physics-based precision
Mechanical, electrical, and process anomalies — not noise
3.
Prescribe exact corrective action
801 prescriptions. 93.47% execution rate. Diagnostic → Recommendation → Action
4.
Validate outcomes. Close the loop.
Plant Heads & Production Managers validate results in PlantOS™ Digital Reporting
Reliability
Throughput
Energy Efficiency
3 Guaranteed Outcomes. 0 Guesswork.
Infinite Uptime has improved our plant reliability and helped us avoid surprise breakdowns. I truly value the real-time alerts — they draw our attention to changes instantly, allowing us to act early and plan maintenance systematically. This has made a real difference for us.
Mr. Ramesh Dham
Digital Manufacturing Head, Coromandel International
Full Transformation Story
GET THE COMPLETE PICTURE.
The numbers above are the headline. The full story reveals the real challenges Coromandel faced — manual monitoring gaps, reactive maintenance cycles, and frequent unplanned stoppages across a complex multi-plant network — and exactly how PlantOS™ flipped the script, delivering user-validated outcomes at every stage of the operation.
✔
Real PlantOS™ Diagnostic Reports from live Coromandel deployments
✔
Equipment-level fault detection across mechanical, electrical & process domains
✔
The 99% Trust Loop™ framework — step by step
✔
User-validated outcome data, confirmed by Coromandel’s own Production & Reliability team
Download the Full Transformation Story
Infinite Uptime · 946 plants · 26 countries · Production Outcomes. Delivered.
Thank you for your interest in
PlantOS™ Prescriptive AI.
Enter your official work email to unlock specs delivering
3 outcomes in 1 prescription — zero guesswork.
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