The verdict in three sentences
For a plant with 3 bottling lines, a sensor-fed real-time dashboard costs USD 25,000 to 50,000 in 2026 including installation (15,000,000 to 30,000,000 FCFA for the same scope in Douala). It calculates OEE (overall equipment effectiveness) minute by minute, sends an SMS alert to the shift lead as soon as a line stops for more than 3 minutes and builds a usable downtime history. The realistic goal is to move OEE from 58 % to 70 % in 6 to 9 months, provided supervisors use the data every day.
What we measure and with what hardware
There is no need to replace machines: simple sensors go on key points, plus one gateway per line that forwards data even over an unreliable connection.
| Measurement point | Sensor or source | Indicative unit cost | Data produced |
|---|---|---|---|
| Blow moulder output | Photoelectric counting sensor | USD 250 to 500 | Preforms and bottles per minute |
| Filler | PLC run and stop signal | USD 330 to 830 (interface) | Machine state, speed |
| Labeller | Presence sensor | USD 250 to 500 | Micro-stops |
| End of line (shrink wrapper) | Pack counter | USD 330 to 670 | Good output |
| Quality check | Tablet scrap entry | USD 400 per tablet | Scrap by cause |
| Gateway per line | Industrial 4G and Ethernet box with buffer | USD 1,500 to 3,000 | Data upload, storage during outages |
| Backup power | UPS for gateway | USD 250 to 500 | Continuity during power cuts |
The local buffer matters everywhere, and is critical in Douala: power cuts and unstable networks must not leave gaps in the history.
2026 budget for 3 lines
| Item | Range (USD) | Range (FCFA, Central Africa) | Comment |
|---|---|---|---|
| Line audit and measurement plan | 2,000 to 3,300 | 1,200,000 to 2,000,000 | 3 to 5 days on site |
| Sensors and gateways (3 lines) | 8,300 to 16,700 | 5,000,000 to 10,000,000 | Depends on PLC interfacing |
| Installation and wiring | 3,300 to 6,700 | 2,000,000 to 4,000,000 | Planned line stop |
| OEE platform and dashboard | 6,700 to 14,000 | 4,000,000 to 8,500,000 | Shop floor screens, web, mobile |
| SMS and WhatsApp alerts, downtime causes | 2,200 to 5,000 | 1,300,000 to 3,000,000 | Operator cause entry |
| Training and 3-month coaching | 2,500 to 4,300 | 1,500,000 to 2,500,000 | Daily 15-minute huddles |
| Total | 25,000 to 50,000 | 15,000,000 to 30,000,000 | 10 to 14 weeks |
| Recurring cost | 400 to 900 a month | 250,000 to 550,000 a month | Hosting, SMS, maintenance |
OEE is availability x performance x quality. An OEE of 58 % often means 75 % availability, 82 % performance and 94 % quality.
What actually raises OEE
The dashboard gains nothing on its own. Gains come from three habits: the 15-minute daily huddle on the top 3 downtime causes from the day before, fast response thanks to SMS alerts (a stop detected in 3 minutes instead of 25) and tracking format changeovers, often the biggest loss in beverage plants.
Mini case study
Mark, plant manager at a water and beverage producer in New York State, runs 3 lines rated at 12,000 bottles an hour each, 2 shifts a day. At 58 % OEE, he produces about 334,000 bottles a day.
- OEE raised to 70 %: 403,000 bottles a day, 69,000 more.
- Contribution margin estimated at USD 0.05 per bottle: USD 3,450 a day.
- Over 25 production days: about USD 86,000 extra margin a month, if demand follows.
- Project at USD 40,000 plus USD 700 a month.
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Even selling only half of the extra volume, payback stays under 1 month. In Douala, at 25 FCFA margin per bottle and a 24,000,000 FCFA project, payback stays under 2 months.
FAQ
Do we need recent machines to install sensors?
No. On older machines without an accessible PLC, external sensors at USD 250 to 500 are enough to count output and detect stops.
What happens during a power or network outage?
The UPS-backed gateway stores up to 7 days of data and uploads it on reconnection. No stop is lost.
How long before OEE improves?
The first points come within 4 to 8 weeks thanks to faster response. Moving from 58 % to 70 % usually takes 6 to 9 months.
Do operators have to enter anything?
Yes, the cause of any stop over 3 minutes, in 2 taps on a tablet. It takes under 10 seconds and makes the history usable.
Can we start with one line?
Yes. A pilot on the busiest line costs USD 11,500 to 16,500 and serves as a benchmark before rollout.
Let's scope your project. Describe your lines, speeds and PLCs, and we will price a real-time dashboard between USD 25,000 and 50,000, live in 10 to 14 weeks. Detailed quote within 48 h. WhatsApp +221 77 596 93 33.
Mohamed Bah
Fondateur, Kolonell
Passionate about digital and entrepreneurship in Africa, Mohamed has been helping Sénégalese businesses with their digital transformation since 2020. Founder of Kolonell, he believes every SME deserves a professional and accessible online présence.
