four zones · complete tortillería.
A Mexican mid-format industrial tortillería has four operational fronts: gas LP comal/oven with precise T, masa cold storage + raw materials (corn/MASECA), LP gas life-safety + plant IAQ, CFE GDMTO sub-metering + stored grain (aflatoxins in warehouse). AstreaIoT covers all four with the same platform.
200-260°C gas LP comal/oven
PT100 surface probe per comal or gas LP oven (typically 200-260°C cooking) · continuous log · alert if out of band · high-temperature probe. Compatible with flat comales (traditional chain) and modern rotary ovens (Tortimax / CIME).
masa cold storage + raw materials
T probe per masa walk-in cooler (target 4-7°C) + raw-materials cold room (refrigerated grains if applicable) · door sensor + compressor current meter · immediate WhatsApp alert if T rises. NOM-251 cold chain compliant.
LP gas detection + plant IAQ
Combustible gas detector in tank area and cooking line · immediate alert + automatic ventilation · STPS NOM-005 compliant. Multi-parameter T+RH+CO₂ sensor in operation zone · IAQ defended for workers.
CFE GDMTO sub-metering + stored-grain humidity
main-panel meter with 12 current channels + 3 voltages · per-line CFE sub-metering (cooking · refrigeration · packaging · stored grain). RH probes in corn silos/warehouse · preemptive aflatoxin if high RH + high T.
Out of scope: forming-cooking machine operation (that's your equipment manufacturer · typically CIME, Tomásito, Tortimax). Also not masa formulation — that's your nixtamalero. We integrate via Modbus with your PLC if it exists.
what we protect · what we prevent.
- +Comal/oven with precise T · standard tortilla · backed NOM-187 audit
- +Validated masa cold storage · cold chain compliant · NOM-251 + COFEPRIS without findings
- +LP gas watched 24/7 · STPS compliant · explosion + accident avoided
- +Per-line CFE GDMTO sub-metering · justified power factor · quantifiable savings
- +Stored-grain humidity watched · preemptive aflatoxins · avoided raw-material loss
- ✕Comal 280°C summer without alert · burnt masa · line stop · lost shift · NOM-187
- ✕Walk-in masa fails overnight · masa at 18°C ambient · bacterial fermentation · entire batch discard · COFEPRIS
- ✕Undetected overnight LP gas leak · accumulation · ignition · explosion · lives + plant destroyed
- ✕0.80 GDMTO power factor · invisible CFE penalty · capacitor bank without data
- ✕Aflatoxins in grain warehouse without alert · NOM-187 + NOM-247 compromise · fine + recall
eight use cases · four critical areas.
for the plant manager + nixtamalero.
Plant Manager + Nixtamalero + Line Operator. Two cases · summer overheated comal without alert, rotary oven with inconsistent T between zones. Quality + uptime.
for the production lead + cold-chain lead.
Production Lead + Cold-Chain Lead + Operator. Two cases · long-weekend walk-in masa fails, raw-material cold room with door ajar. NOM-251 + daily batch.
for the safety lead + STPS lead.
Safety Lead + STPS Lead + Plant Manager + Maintenance. Two cases · undetected overnight LP gas leak, plant IAQ with high CO₂ + inadequate ventilation. Life + STPS.
for the CFO + supply-chain lead.
CFO + Supply-Chain Lead + Plant Manager. Two cases · low GDMTO power factor, high humidity in stored grain with aflatoxins. Costs + supply chain.
three compliances · one platform covers all three.
For multi-site tortillería chains (Tortimax, Tortillería del Centro), cross-property dashboard with compliance ranking + consolidated CFE sub-metering.
from sensor to report · every five minutes · without human intervention
Five steps. They run in parallel across all your sites, all the time. When something crosses a threshold, the flow completes in under five minutes — alert delivered, response logged, inspector-ready evidence captured.
measure
Sensors measure temperature, humidity, current, door-open, leak and other magnitudes every five minutes — no operator required.
detect
The system compares each reading against the threshold configured per recipe · per site · per equipment. Threshold crossing triggers the flow.
alert
The alert routes to the right person via WhatsApp, email or push · per role and schedule configured.
respond
The operator acts from the dashboard or mobile app. The corrective action goes into an immutable log with timestamp + signature.
audit
Everything becomes part of the audit package · time series, critical events, corrective actions, NOM report ready in two clicks.
Five steps · no manual operators · no paperwork · no gaps.
five phases · per tortillería.
site survey + plant plan
1-2 daysTechnical visit + inventory of comales/ovens, walk-in masa, raw-materials cold rooms, LP gas tanks, CFE panel, corn warehouse · deployment plan.
physical installation
2-4 daysComal-surface PT100 probes + walk-in masa T probes + LP gas sensor + multi-parameter IAQ sensor + CFE meter + warehouse RH probes · gateway with backup · without affecting production.
configuration + PLC integration
1-2 weeks (includes Custom L3 if your plant has PLC)Per-product comal thresholds + LP gas alerts + cold chain + sub-metering · NOM-187 + COFEPRIS report templates · Modbus PLC integration.
team training
1 dayPlant Manager + Nixtamalero + Cold-Chain Lead + Safety Lead + CFO + Operators · each role trains on their flow.
30 days of support + first audit
30 daysAstreaIoT specialist available · first monthly report with comal + masa + LP gas + sub-metering + aflatoxins · first backed NOM-187 audit.
For multi-site tortillería chains, per-plant deployment with standardized BOM.
common questions · before the quote.
does it integrate with my forming-machine PLC?
Yes · Custom Integration L3 · Modbus TCP or RTU with your PLC (CIME, Tomásito, Tortimax). Comal + cold chain + sub-metering data feeds your central system.
does the PT100 probe continuously withstand comal T?
Yes · temperature probe (operational 200-280°C, peaks up to 500°C) · refractory + resistant cable. Calibrated in accredited laboratory.
what about LP gas detection?
Gas detector in tank area + cooking line · immediate alert + automatic ventilation activation + optional access blocking. STPS NOM-005 compliant. Your personnel protected 24/7.
are NOM-187 + NOM-247 (aflatoxins) audits backed?
Yes · pre-configured templates for NOM-187 tortilla + NOM-247 aflatoxins + monthly report with comal + cold chain + sub-metering + warehouse RH · COFEPRIS your Responsable Sanitario hands the evidence packet to the auditor.
how is pricing for a mid-format tortillería?
Per-line model: SaaS fee per comal/oven + masa walk-in + life-safety + sub-metering + grain warehouse. Approximately between several thousand and a few thousand pesos monthly depending on scale. 90-day Hybrid Pilot default.
does it integrate with tortillería chains (Tortimax, Tortillería del Centro)?
Yes · cross-property dashboard + compliance ranking + consolidated sub-metering · ideal for corporate with multi-site.
are premium-supplier certifications (Walmart-supplier, supply chain) backed?
Yes · inspector-ready report aligned with large-chain expectations (Walmart, Soriana, HEB) · sub-metering + cold chain + LP gas defensible vs supply chain audit.