See the savings. Before we install anything.
The same six levers pay back in almost every plant. Try each one with your own numbers, then see exactly which device and protocol it needs.
Slow the motor, not the flow.
Most fans and pumps run at full speed and throttle the flow with a damper or valve. A variable speed drive slows the motor instead, and power falls with the cube of speed.
Devices to connect
| Device | Measures | Protocol | Notes |
|---|---|---|---|
| Variable speed drive | Speed, kW, current, faults | Modbus RTUProfinetEtherNet/IP | The control point. It also reports its own energy. |
| Motor energy meter | kW, kWh, power factor | Modbus TCP | For motors without a drive yet. |
| Pressure or flow transmitter | What the process needs | 4–20 mAHART | Lets PlantOS slow the motor to demand. |
| Vibration and temperature sensor | Bearing health | IO-LinkModbus RTU | Stud-mounted on each bearing. |
How the data flows
Field signals reach the PLC or an RS-485 gateway. The edge gateway in your plant translates them into one standard stream, and setpoints return the same way. Your PLC applies its own limits.
Your most expensive utility leaks all day.
US Department of Energy data puts leaks at 20–30% of compressor output in poorly maintained systems, and under 10% where leaks are managed. Running pressure higher than the line needs costs more on top.
Devices to connect
| Device | Measures | Protocol | Notes |
|---|---|---|---|
| Compressed-air flow meter | Air used per line, leaks at rest | 4–20 mAModbus RTU | Thermal mass meter on each main header. |
| Pressure transmitter | Header pressure | 4–20 mA | Shows how far pressure can safely drop. |
| Compressor energy meter | kW, load and unload hours | Modbus TCP | Gives kW per cubic metre per minute. |
| Ultrasonic leak detector | Leak location and size | Field app | Monthly survey logged against each leak tag. |
How the data flows
Field signals reach the PLC or an RS-485 gateway. The edge gateway in your plant translates them into one standard stream, and setpoints return the same way. Your PLC applies its own limits.
Buy heat. Not water.
Firewood, bagasse and briquettes are bought by weight or volume but burned by energy content. Wet fuel and too much excess air both send money up the stack.
Devices to connect
| Device | Measures | Protocol | Notes |
|---|---|---|---|
| Flue gas O₂ analyser | Excess air | 4–20 mAHART | Zirconia probe after the boiler, before the stack. |
| Steam flow meter | Steam generated and used | 4–20 mAHARTModbus | Vortex meters on the header and large users. |
| Pressure and stack temperature | Header pressure, flue temperature | 4–20 mA | Warn of fouling and excess air. |
| Steam trap monitor | Trap failed open or blocked | WirelessHARTModbus TCP | Battery wireless; no cables on hot lines. |
| Fuel moisture meter | Moisture per delivery | Field app | Five readings per truck, priced per gigajoule. |
How the data flows
Field signals reach the PLC or an RS-485 gateway. The edge gateway in your plant translates them into one standard stream, and setpoints return the same way. Your PLC applies its own limits.
Stop paying for power you never use.
Induction motors draw reactive power that raises your kVA demand and your bill without doing any work. Capacitor stages and a demand manager keep you under your contract limit.
Devices to connect
| Device | Measures | Protocol | Notes |
|---|---|---|---|
| Power-quality analyser | kW, kVA, PF, harmonics, sags | Modbus TCP | At the main incomer. |
| Section sub-meters | kWh per line or MCC | Modbus TCPModbus RTU | One per major load centre. |
| Utility meter reading | Billing kWh and demand | DLMS/COSEM | With the utility’s consent, or a check meter. |
| Capacitor bank controller | Stages switched, PF target | Modbus RTU | Use detuned reactors where drives create harmonics. |
| Genset controller | Load, fuel, run state | Modbus RTUModbus TCP | Outage detection and priority loads. |
How the data flows
Field signals reach the PLC or an RS-485 gateway. The edge gateway in your plant translates them into one standard stream, and setpoints return the same way. Your PLC applies its own limits.
Hear a bearing fail weeks before it does.
A damaged bearing rings at its own frequencies long before it seizes. PlantOS reads the vibration spectrum of your heavy motors and turns it into a date for the repair.
Devices to connect
| Device | Measures | Protocol | Notes |
|---|---|---|---|
| Vibration and temperature sensor | mm/s RMS, crest factor, bearing °C | IO-LinkModbus RTU | Stud-mounted on drive-end and non-drive-end bearings. |
| IO-Link master | Connects smart sensors | ProfinetEtherNet/IPModbus TCP | One per line; powers and reads the sensors. |
| Motor current from drive or meter | Current signature, load | Modbus TCP | Reveals rotor and load faults too. |
| Wireless vibration sensor | Same, without cabling | LoRaWANWirelessHART | For remote pumps and fans. |
How the data flows
Sensors calculate vibration features on board, so only small values cross the network. Work orders appear in the field app with the machine, the fault and the date to act.
Find the kilos nobody can explain.
Raw material in against product, by-product and waste out, every shift. When the balance does not close, PlantOS shows the stage where it opened.
Devices to connect
| Device | Measures | Protocol | Notes |
|---|---|---|---|
| Weighbridge or intake scale | Raw material in | RS-232RS-485REST | Existing scales read automatically. |
| Belt weighers and flow meters | Material between stages | 4–20 mAModbus RTU | Where product moves continuously. |
| Bin and pack scales | By-product, waste and product out | Modbus RTUEthernet | Every output stream weighed. |
| Checkweigher | Pack weight and giveaway | OPC UA | Cuts overfill on every pack. |
How the data flows
Each scale is read automatically and tagged with the shift and lot. The balance closes per shift, and the stage-by-stage view shows where it opened.
Want these numbers for your plant?
A plant assessment measures each of these levers on your own machines and turns them into one report in shillings.