Built for ASR Group

5 Refineries. 7M Lbs Daily. Zero Visibility. SAP EWM Isn't Built for Continuous Ops.

ASR Group's Chalmette and Baltimore refineries run 24/7 continuous operations producing 7 million pounds of sugar daily. SAP Extended Warehouse Management tracks inventory, but your maintenance teams are still reactive—managing critical equipment failures across five North American refineries without real-time asset intelligence or predictive insights.

See How UpKeep Replaces SAP EWM for Maintenance →
ASR Group
37%
Reduction in unplanned downtime
6+ hrs
Admin time saved per week
75%
Faster compliance audit prep
1,000+
Critical assets tracked per plant
Your ASR Group Account Team
Aaron Kerr
Aaron Kerr
Business Development
Schedule a Call →
ASR Group's Challenges

Built for What Continuous Sugar Refining Actually Demands

Your refineries operate 24/7 with zero tolerance for downtime. A single silo failure—like the 2020 Chalmette fire—can halt production of millions of pounds daily and disrupt holiday-season demand spikes. SAP EWM manages warehouse flow, but it doesn't track equipment health, predict failures, or mobilize maintenance teams before catastrophe strikes.

Finished Product Silos & Storage Systems

Your 10-story silos and finished product storage are critical path assets. SAP EWM tracks what's in them, but not their structural health, temperature sensors, or vibration anomalies that signal imminent failure. When a silo fails mid-shift, you lose millions in production and face emergency repairs.

  • ✓Real-time asset health monitoring replaces manual inspections and SAP EWM blind spots
  • ✓Predictive failure alerts prevent catastrophic silo fires and unplanned shutdowns
  • ✓Mobile work orders mobilize maintenance teams before inventory systems even know there's a problem

Centrifuge & Crystallization Equipment

Centrifuges and crystallization vessels run continuously and wear unpredictably. SAP EWM doesn't track bearing temperature, vibration, or seal integrity—only what product moves through. Unexpected failures halt your refining pipeline and create emergency downtime during peak demand.

  • ✓Condition-based maintenance triggers replace calendar-based schedules and guesswork
  • ✓Vibration and temperature sensors feed directly into work order automation, bypassing SAP EWM delays
  • ✓Predictive analytics identify bearing wear weeks before failure, protecting continuous operations

Evaporator & Boiler Systems

Evaporators and boilers are energy-intensive and prone to scaling, corrosion, and seal failures. SAP EWM tracks steam flow and energy use, but not equipment degradation. Unplanned boiler failures force production halts and spike energy costs during emergency repairs.

  • ✓Automated maintenance scheduling based on actual equipment condition, not SAP EWM inventory cycles
  • ✓Pressure and temperature trending alerts maintenance teams to scaling and corrosion before failure
  • ✓Integration with energy monitoring ensures boiler efficiency is maintained, reducing unplanned shutdowns

Packaging & Bagging Lines

Your packaging lines feed industrial and foodservice customers with tight SLAs. SAP EWM tracks finished goods, but not conveyor belt tension, seal integrity, or motor load—leading to mid-run failures that delay shipments and frustrate customers.

  • ✓Motor load and conveyor health monitoring prevents line stoppages before they impact customer orders
  • ✓Mobile technician dispatch replaces manual SAP EWM work order routing, cutting response time by hours
  • ✓Predictive seal and belt wear alerts let you schedule maintenance during planned downtime, not emergencies

Raw Sugar Milling & Processing Equipment

Your mills in Mexico and Belize process raw sugarcane into feedstock for refineries. SAP EWM tracks raw sugar inventory, but not crusher wear, diffuser scaling, or pump cavitation—leading to supply chain disruptions when equipment fails unexpectedly.

  • ✓Cross-facility asset visibility connects mill equipment health to refinery production planning in real time
  • ✓Predictive maintenance for crushers and diffusers prevents raw sugar supply interruptions
  • ✓Mobile work orders sync maintenance across geographically dispersed mills without SAP EWM delays

Chalmette & Baltimore Continuous Operations Infrastructure

Your transition to continuous operations at Chalmette and Baltimore requires zero-downtime maintenance culture. SAP EWM doesn't support predictive, condition-based work—only reactive fixes that halt production and violate continuous ops commitments.

  • ✓Predictive maintenance scheduling enables maintenance during micro-stops, not full shutdowns
  • ✓AI-powered failure prediction prevents the unplanned downtime that breaks continuous operations
  • ✓Real-time asset intelligence replaces SAP EWM's inventory-only view, enabling true operational resilience
AI-Powered Maintenance

From Reactive Silo Fires to Predictive Equipment Intelligence

UpKeep replaces SAP Extended Warehouse Management's inventory-only approach with AI-powered asset health monitoring across all five refineries. Instead of discovering failures when production stops, your maintenance teams get predictive alerts weeks in advance—preventing catastrophic downtime like the 2020 Chalmette silo fire. Mobile-first work orders, real-time sensor integration, and cross-facility visibility transform your 24/7 operations from reactive firefighting to predictive precision.

1

Mobilize the Plant Floor

Deploy UpKeep mobile app to every technician at Chalmette, Baltimore, California, Maryland, and Canada facilities. Technicians see real-time asset health, predictive alerts, and work orders—no more SAP EWM delays or manual spreadsheets. Maintenance teams respond to failures hours faster.

2

Automate Condition Monitoring

Connect vibration, temperature, and pressure sensors from silos, centrifuges, boilers, and packaging lines directly to UpKeep. SAP EWM tracked inventory; UpKeep tracks equipment health. Automated work orders trigger when conditions signal imminent failure—before production stops.

3

Predict Failures Before They Happen

UpKeep's AI learns your equipment patterns and predicts failures weeks in advance. Schedule maintenance during planned downtime, not emergencies. Prevent silo fires, centrifuge failures, and boiler shutdowns that disrupt continuous operations and holiday-season demand spikes.

4

Operate Autonomously Across All Refineries

Real-time visibility across five refineries, mills in Mexico and Belize, and 1,000+ critical assets. Maintenance, operations, and supply chain teams align on equipment health. Continuous operations run uninterrupted—no more reactive firefighting, no more SAP EWM blind spots.