Industrial automation consulting · Mangaluru
Know what your pumps, compressors, boilers, meters and lines are doing on every shift, without replacing the machines you already run. We start with a 2–3 day on-site assessment or a 30-day pilot on one line, and we put the scope in writing before any work begins.
Corporate office (sales, service and next-business-day work): Monday-Friday, 09:00-17:00 IST. We reply to enquiries within one business day.
This is for owners, plant heads, and maintenance and operations managers at small and mid-size manufacturers in Mangaluru, Udupi and coastal Karnataka, including units in Baikampady Industrial Area and Ganjimutt EPIP.
Probably not for you if you need a full new production line designed from scratch, or a machine builder to write new control logic. We will tell you that on the first call and, where we can, point you to the right people.
Energy meters, flow meters and machine counters are read by hand, entered into a register and typed into Excel at month-end. Readings get missed and nobody trusts the totals. We log them automatically, every few minutes.
Unplanned downtime usually gives warning signs first: rising current, vibration, temperature or run-hours. We watch those signals and send an alert to the right person before the breakdown.
Without a meter on each section, you see one big number from MESCOM. We split energy use by feeder, machine or shift, and flag usage peaks and machines left running when idle.
We put production counts, stoppages and utility status for every shift on one screen, so the morning meeting starts from facts and not from memory.
Utilities are often the biggest energy users and the least monitored. Compressor load and unload, air leaks, boiler pressure and temperature, pump run-hours and tank levels can all go on a dashboard with alerts.
Most PLCs, drives and meters already hold useful data. Where the equipment allows it, we read that data and make it visible to the people who need it.
Temperature logs, cold-room records, batch sheets and maintenance registers can be captured digitally with time stamps. This makes records easier to find when customers or auditors ask for them.
Shared passwords, an old router, the OEM's remote-access tool left open, and office laptops on the same network as the machines. We find these gaps and close the most important ones first, using the same server, network and security discipline Northstar applies to enterprise infrastructure.
All prices are starting points. We confirm a fixed price in writing after the first call. Taxes and any travel terms are set out in the written quote.
A clear written picture of where automation will save money in your plant, and where it won't.
Who it suits: Owners and plant heads who want a practical, priced plan before they spend on hardware or software.
Duration: 2–3 days on site, then a written report. The delivery date is agreed in your quote.
From ₹40,000 (up to about ₹1.25 lakh for larger or multi-line plants). Assessment fee credited against a Connected Operations Pilot when terms in your quote allow.
One line, one pump set or one energy feed, monitored live for 30 days. Then you decide whether to expand.
Who it suits: Plants that know their main problem area and want real data before a full rollout. This is the plant version of Northstar's Connected Operations Pilot.
Duration: Setup time agreed before we start, then 30 days live monitoring and a go/no-go review.
From ₹1.5 lakh for services, plus hardware at cost or bought direct. Hardware you own or paid for stays with you after the pilot.
A senior automation and IT advisor for your plant, a few days every month, without a full-time hire.
Who it suits: Owners planning automation, SCADA, ERP connection or a new line, and plants rolling out after a successful pilot.
Duration: 2–4 days per month, on site and remote. The term is agreed in writing.
From ₹40,000 per month for 2 days per month. Additional days quoted in advance.
| Readiness Assessment | 30-Day Pilot | Fractional Advisor | |
|---|---|---|---|
| Best for | Where should we start? | Prove it on one line | Help us plan and buy right |
| Time | 2–3 days on site + report | Setup + 30 days live | 2–4 days/month |
| Main output | Top-3 opportunities, roadmap, scheme note | Live dashboard, alerts, go/no-go report | Roadmap, bid reviews, network hygiene |
| From | ₹40,000 (up to ~₹1.25 lakh) | ₹1.5 lakh + hardware at cost | ₹40,000/month |
Not sure which one fits? Book a 30-min plant call and we'll recommend one, or tell you if you don't need any of them yet.
You can join at step 1, 2 or 4. Every step ends with a written output and a decision that belongs to you. See the full delivery method on How We Work.
30-min plant call. We learn what you make, what goes wrong and what it costs you. If we are not the right fit, we say so on this call.
Plant Automation Readiness Assessment on the plant floor: assets, energy, controllers and network in writing.
Practical scope, phased roadmap and commercial proposal in the assessment report, including what we will not do.
30-Day Connected Operations Pilot on one line, pump set or energy feed before a wider rollout.
Scoped separately after a go: roll out, test, document and train so the system runs without us in the room.
Fractional Automation Advisor or a written support agreement. Or a clean handover with full documentation.
Two schemes may help eligible MSMEs pay for consultancy and technology upgrades. Northstar helps you check whether a scheme may apply and prepare technical documents. We help with paperwork; we don't guarantee approval, the amount or the timeline.
MSMEs with ZED certification at Bronze level or above can apply for handholding support of up to ₹5 lakh per MSME, including up to ₹2 lakh for consultancy and up to ₹3 lakh for technology upgrades toward cleaner technology and pollution-control measures.
Subsidy rates are 80% for micro, 60% for small and 50% for medium enterprises, subject to scheme rules and committee approval. Check with the ZED portal or your nearest MSME-DI whether the scheme is open for new applications.
Support of up to ₹5 lakh per MSME to implement Industry 5.0 solutions, limited to 100 companies each year across the policy period. Whether a particular automation or monitoring project qualifies is decided under the state's guidelines.
Scheme details change. Always check current guidelines with the issuing authority before applying.
Simulated data, not a customer site. See live readings, alerts, shift-wise energy use and history as an operator and plant head would. We walk you through it on a call or at your plant.
Ask for a demo walkthroughCase studies and labelled demos. We publish plant examples only with the client's written permission.
The Plant Automation Readiness Assessment starts from ₹40,000, depending on plant size. The 30-Day Connected Operations Pilot starts from ₹1.5 lakh plus hardware at cost. The Fractional Automation Advisor retainer starts from ₹40,000 per month. We confirm a fixed price, taxes and any travel terms in writing before any work starts.
Usually not. Most of the work is reading data from meters and PLCs that are already installed, or adding clamp-on and surface-mounted sensors. Any job that needs a machine stopped or a panel opened is planned with your maintenance team for a scheduled shutdown or a shift change.
In most cases, yes. Older machines without a PLC can still be monitored with retrofit sensors for current, temperature, vibration, pressure or run-hours. Newer machines and energy meters often already provide the data we need. The assessment tells you exactly what is possible on each machine.
You own your plant data. Where it is stored is agreed with you in writing, and you can export it at any time. We keep the machine network separate from the office network, use named logins instead of shared passwords, and give remote access only with your permission. At the end of an engagement, we hand over all logins and documents.
We are vendor-neutral and don't push any brand. If sensors, gateways or meters are needed, we specify them and supply them at cost, or you can buy them directly. Any hardware you own or have paid for stays with you. Our fee is for the consulting and engineering work.
Possibly. MSMEs with ZED certification at Bronze level or above may apply for up to ₹5 lakh of handholding and technology-upgrade support, subsidised at 80%, 60% or 50% depending on enterprise size. The Karnataka Industrial Policy 2025–30 offers up to ₹5 lakh per MSME to implement Industry 5.0 solutions. All support depends on scheme eligibility and approval. We help with the paperwork, but we can't guarantee approval.
We are based in Hampankatta, Mangaluru, and work on site across Dakshina Kannada and Udupi, including Baikampady and Ganjimutt EPIP. Other locations can be discussed, with remote support between visits.
You receive a go/no-go report. If the result is go, we give you a scoped and priced plan to expand to more lines or plants. If it is no-go, you keep the data, the report and any hardware you own or have paid for, and you don't owe anything more. You can also continue with the Fractional Automation Advisor retainer or a support agreement.
Five details are enough to start. We will call you back at the time you choose.
Tell us what you make, which machine or utility worries you most, and how you track it today. Within 30 minutes, you'll know whether a Readiness Assessment, a 30-day pilot or an advisor retainer makes sense, or whether you don't need us yet.
Northstar Enterprise Solutions Private Limited · LG4, Maximus Commercial Complex, Lighthouse Hill Road, Hampankatta, Mangalore 575001 · info@northstar-es.in