Plant Reliability Solutions for
Metals Industry

Empower plant operations and maintenance. Mitigate machine failures.
Minimize unplanned downtime. Achieve digital reliability.

Online Monitoring & Diagnostics for Equipment in the Aluminum Industry

Green Anode Plant (GAP)
Ball Mill Bucket Elevator ID Fan Kneader Paste Mixer

Baking Furnace
FTA Blower FTA Compressor FTP ID Fan

Rodding
Autogenous Mill Belt Conveyor Shot Blast Unit Dust Collector Fan Butt Press Pump

Potline
Circulation Blower ID Fan Belt Conveyor

Cast House
Ingot Transfer Fork Cooling Conveyor Layer Conveyor Stack Conveyor Casting conveyor Wire Rod Mill Cooling Tower Saw Cutter Air compressor Pit Pump Crane Billet Cutter

Rolling
Rough Rolling Stand Finish Rolling Stand Anealing Cooler Fan

Powerplant Boiler Feed Pump PA Fan SA Fan ID Fan CEP Pump Vacuum Pump Cooling Water Pump Demineralization Pump Gas Turbine Cooling Tower Fan

The aluminium industry, a fundamental part of contemporary manufacturing, encounters several obstacles that can impede its effectiveness and total output. The process of producing aluminium involves severe conditions. Furnaces and cells in potrooms function at elevated temperatures, generating intense heat that can negatively impact machinery. Furthermore, the production process creates substantial dust, which can obstruct machinery and decrease efficiency.
A primary concern in the aluminium industry is the safety of its workers. The production process exposes workers to various risks that advanced sensor solutions can alleviate. Employees in the sector are exposed to a variety of hazards. These include the risk of touching hot metal, which can lead to serious burns or injuries. They also face electrical dangers, which could result in electrocution. There is a possibility of becoming ensnared in machinery, resulting in crushing injuries. Furthermore, they might be exposed to dangerous gases like fluorine gases and polycyclic aromatic hydrocarbons, which can negatively impact their health.
Currently, the aluminium industry is undergoing significant transformations due to technological advancements. Technology plays a crucial role in shaping the future of aluminum production, from extraction and manufacturing processes to recycling and energy efficiency. The industry is experiencing a paradigm shift that boosts productivity, sustainability and safety, thanks to digital condition monitoring and asset performance management.
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Improving Operations & Reliability in the Aluminum Industry

Four out of five companies lack the data or ability to calculate downtime costs accurately. Digitalization can be a critical enabler of productivity and process improvements by identifying the top causes of downtime. A global Cement manufacturer increased total factory uptime by 1088 hours with plant reliability solutions.
Strengthen production levels, eliminate unplanned cement plant downtime, and make plant maintenance stress-free with AI-enabled Predictive Maintenance solutions designed for Cement Industry.
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Plants
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Equipment
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Hours of
Downtime Prevented
Applications
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Feeder
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Conveyer
Crusher
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Bag-House Blower
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Compressor
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Cooling Tower
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Exhaust Fan
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Gearbox
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Autogenous Mill
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Rodding
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Utility
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The Mining and Metal industry is progressively adapting to an evolving global business climate, exponential demand for cost-effective products in developing economies, and increasingly stringent environmental policies.
Asset reliability takes centre-stage when cost efficiency and maximal machine uptime can provide a competitive advantage. Metal production plants can’t afford sudden machine failures, unplanned downtime and the risk of hazardous leakages or explosions due to poor plant reliability measures.
A responsive Predictive Maintenance approach can enable achievement of plant reliability objectives with data-backed insights empowering plant maintenance and operation teams.
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Predictive Maintenance and Digital Reliability for next-gen Aluminum Production plants

Asset condition and process visibility in real time can potentially bring down metals plant maintenance costs and mitigate unplanned downtime. Digitalization and AI-enabled predictive analytics can change the way plant reliability is approached for mining and metals industry.World’s largest aluminium producer capitalized on predictive analytics and plant reliability solutions to save 310 hours of factory downtime.
Optimize plant and process efficiencies with real-time information, analytical insights, and asset reliability solutions designed for Mining and Metals Industry.
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Asset Protection and Reliability

Unreliable assets are responsible for unplanned downtime and process disruption. Utilize real- time asset health information from remote locations to plan maintenance events with minimal disruption of plant operations.
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Optimize Production and Yield

Assuredly operate assets at rated capacities to maximize plant uptime and the resultant yield. Enable data-driven manufacturing with digital-first approach and avoid eventualities that can negatively impact plant production or output.
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Achieve Cost Efficiencies

Empower plant maintenance teams with responsive digital reliability solutions designed for metal plants. Reduce plant downtime multi-fold with auto-diagnostics data available in real-time and syndicated maintenance recommendations to support decision-making.
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Brands that Trusts Us

Maximize plant reliability and take your plant performance to the next level.

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