Agnaris Perdas
Where the operation loses raw material and sugar, from the field to the plant.
How much is lost between the field and the plant, at what stage and why?
Agnaris Perdas brings together field records, the weighbridge, the laboratory and the plant systems to show how much is lost, at what stage and in what situation. In sugarcane, that runs from the time between burning and crushing to the sugar that leaves the plant with no known destination. Nothing is installed: we start with exports from the systems the operation already uses.
In each sector
The same product answers different questions in each production chain. Choose yours.
How much sugar is lost between burning and crushing, and how much disappears inside the plant?
Each load is linked to the front, the time of burning or cutting and its arrival at the weighbridge. Cut cane left standing loses close to 2% of its sugar per day, so Perdas shows the fronts that go past 36 hours. At the plant, the balance by stage and shift separates the known loss (bagasse, filter cake, final molasses) from the loss that disappears with no explanation, and points to the meter that does not balance.
- Data used
- Burning, cutting and loading by front
- Weighbridge and laboratory: ATR and impurities
- Industrial bulletin and supervision system
- Map of farms and fronts
- Deliverables
- Time from burning to crushing by front
- ATR balance by stage and shift
- Meters to recalibrate and calculated values where there is no measurement
- 38 hbetween burning and crushing on the slowest front
- 1.1%of ATR lost with no known destination on the night shift
- 2flow meters out of calibration
Example numbers
At what stage does the fruit lose export grade, and which lots are most at risk of a complaint at destination?
At the packing house, each mango pallet carries the lot, the harvest date, the time to the cold room and the grading. Perdas cross-checks packing house rejects with the block, the rain before harvest and the handling, and shows which lots are most likely to reach the importer with anthracnose.
- Data used
- Harvest record by lot
- Packing house grading and rejects
- Cold room temperature
- Importer complaints
- Deliverables
- Rejects by lot and by stage
- Complaint risk by lot, before shipping
- Time between harvest and cooling
- 9%rejected at the packing house in the lot with the most rain before harvest
- 3 hbetween harvest and cold room in the problem lot
- 2lots held back for the domestic market before shipping
Example numbers
Which collection routes and times worsen the quality of the milk that reaches the dairy?
The dairy already receives the bacterial count and the somatic cell count of each producer. Perdas adds the route, the collection time and the time to the tank, and shows which routes and producers need a technical visit before the milk or the bonus is lost.
- Data used
- Collection routes and schedules
- Volume by producer
- Bacterial count (CBT) and somatic cell count (SCC) analyses
- Tank temperature
- Deliverables
- Quality by route and by producer
- Alert for collection outside the schedule
- List of technical visits
- 2routes with collection time above the limit
- 310,000CFU/mL average bacterial count on route 4
- 240producers linked to their collections
Example numbers
How much do the intake pit queue and high moisture cost in shrinkage and drying?
At the warehouse, each truck is linked to its source block, the moisture and impurities measured at intake and the waiting time. Perdas shows shrinkage and drying cost by origin and what the queue costs at the harvest peak.
- Data used
- Harvest delivery slips
- Intake grading: moisture and impurities
- Weighbridge and intake pit queue
- Dryer consumption
- Deliverables
- Shrinkage and drying by origin
- Queue time and cost of waiting
- Suggested intake order
- 18%average moisture in the loads from block 7
- 2 h 40average wait at the intake pit at peak
- R$ 11per tonne of extra drying on wet loads
Example numbers
Try it
Change the time between burning and crushing of a load of cane and see what happens to its sugar and its value.
Load 4473 record
- Origin
- Farm 09, front 2
- Burning
- Mon 20:30
- Arrival at the weighbridge
- ter 16:30
- Measured ATR
- 135,0
- Sugar lost while waiting
- 1,2 %
- Value lost on this load
- R$ 45
Within the limit: the load arrives well before 36 h.
Simplified model, for demonstration only.
The same seven weeks of season
Without monitoring, one in four loads goes past 36 hours between burning and crushing, and the unaccounted loss at the plant does not change. With Perdas, slow fronts show up within the shift and meters that do not balance are recalibrated.
Without Agnaris
Loads over 36 h %
ATR lost with no destination %
Without AgnarisClose to 24% of loads over 36 h and 1.4% of ATR with no destination
With AgnarisLess than 8% over 36 h and the unaccounted loss falling to 0.7%
IllustrativeDrag to compare
How it works
Who it is forPlants that receive raw material from many fronts, lots or routes and need to know where and why they lose quality and product.
- Record
Each load, lot or collection is linked to its area of origin, the time of burning or harvest, transport and arrival.
- Balance
Weighbridge, laboratory and plant bulletin close the account by stage and shift, separating known loss from unaccounted loss.
- Alert
When a front goes past the time limit, a lot loses its grade or a meter stops balancing, the team is notified in the same shift.
What the team sees
| Load | Farm | Burning | Weighbridge | Time | ATR |
|---|---|---|---|---|---|
| 4471 | Farm 14 | Tue 14:10 | Wed 09:42 | 19 h 32 | 136.8 |
| 4472 | Farm 14 | Tue 14:10 | Wed 10:05 | 19 h 55 | 137.2 |
| 4473 | Farm 09 | Mon 20:30 | Wed 10:48 | 38 h 18 | 131.4 |
| 4474 | Farm 12 | Tue 16:40 | Wed 11:02 | 18 h 22 | 135.9 |
| 4475 | Farm 09 | Mon 20:30 | Wed 11:31 | 39 h 01 | 130.7 |
Front 2 (farm 09): loads more than 36 h past burning. ATR 4% below the other fronts.
How the alert reaches the phone
- Agnaris:
Front 2: 6 loads cut yesterday afternoon still in the field, 30 h since burning. If they go past 36 h, the estimated loss is 3% of the sugar.
- You:
How many trucks does it need?
- Agnaris:
With 2 more trucks until 10 am, all of them arrive before 36 h. Front 1 is ahead of schedule and can spare the 2.
- You:
Sending the two from front 1.
What you need to get started
- History
At least one season of data: crushing or production, stoppages and, if available, rain and quality. A spreadsheet is fine.
- Access
Exports or read access to the systems that hold this data. We change nothing in them.
- One person
Someone from the operation who knows the data and can answer the technical team's questions a few hours a week.
Questions about Agnaris Perdas
Do I need to install sensors or readers?
To start, no. We use the records that already exist: cutting orders, weighbridge, laboratory and the plant bulletin. Where field records are missing, Agnaris Campo fills the gap. A physical sensor only comes in if the analysis shows it is worth the cost.
How do you access the plant data?
We start with scheduled exports from the bulletin and the supervision system, with no link to the industrial network. Direct access only later, if IT and automation approve, and always read-only.
What is unaccounted loss?
The difference between the sugar that entered the plant and the sum of what left as product plus the measured losses: bagasse, filter cake and final molasses. Every mill has it; Perdas shows at what stage and in what shift it grows.
The other products
- Agnaris Clima Rain and calendar turned into operating decisions. On which days will the rain stop the field, and what should be done before it? Learn about Agnaris Clima
- Agnaris Campo Field records on the phone, with or without internet. What happened on each front today, and at what time? Learn about Agnaris Campo
- Agnaris Fornecedor Payment for quality checked load by load. Does what was paid to each supplier match the weight and quality of what they delivered? Learn about Agnaris Fornecedor
Talk to the team
Tell us what your operation produces and what data it already has. The first conversation is with the technical team.