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Infinite Uptime - Solutions
PlantOS™ Prescriptive AI

Prescriptive Maintenance Solutions
for Plant Reliability.

One Vertical AI platform. A purpose-built AI solution for every equipment class in your plant, organised by industry and deployed in weeks.

PlantOS™ delivers prescriptive maintenance as four solutions, one for each tier of equipment in a heavy manufacturing plant. Where generic tools raise alerts, PlantOS™ issues a prescription: the specific component at fault, the corrective action, and the outcomes to be achieved. Operators validate every prescription, so the AI learns from real outcomes across 946 plants.

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Why PlantOS™ Delivers Plant Reliability

Plant Reliability

The umbrella outcome: less downtime, lower maintenance cost, and longer equipment life across every line.

Equipment-Specific Intelligence

Each solution is pre-trained on thousands of failure signatures for that exact equipment class, not on a generic model.

Quantified ROI

Every prescription is validated by operators and documented for board-level ROI reporting.

EQUIPMENT-SPECIFIC AI

What are the four PlantOS™
prescriptive maintenance solutions?

PlantOS™ covers the full criticality spectrum, from the flagship equipment that defines your output to the balance of plant that has never been monitored at all.

01

AI Shields purpose-built for the equipment.

Deeper vertical depth - trained on equipment-specific failure signatures across heavy manufacturing.

AI Shields are prescriptive maintenance solutions built for a single class of production-critical heavy industrial equipment, specifically kilns, mills, cranes, furnaces, & more. Each Shield uses Dynamic FMEA to correlate mechanical signals with live process conditions, which lets it identify failure modes that generic vibration monitoring cannot see. Common faults detected include thermal fatigue, material build-up, cyclone jamming, oil contamination, gear-mesh backlash, & more.

Steel & Metal

Steel & Metal Solutions

Protect the assets that keep your furnaces running.

Crane AI Shield

Heavy industrial crane AI covering hoist motors, rope drum, end-carriage bearings,
and ladle transfer sequences. Prevents catastrophic failures in live zones.

Overhead, Ladle & Gantry Cranes

Faults Detected

  • Hoist motor bearing failure
  • Rope drum & sheave wear
  • End-carriage wheel & rail wear
  • Brake & gearbox degradation

Impact

1 prescription = 4 hours of unplanned downtime avoided on the EOT ladle crane.

~$750K* in production protected at Tata Steel by a single call.
*Production-protected values are conservative estimates, combining industry-standard downtime benchmarks with validated Infinite Uptime prescription data.

Explore the Crane AI Shield
Roll AI Shield

Real-time monitoring of rolling mill stands, work rolls, and backup rolls. Detects bearing faults,
roll surface defects, and chock misalignment before they cause strip breaks or quality rejects.

Rolling Mill Stands

Faults Detected

  • Work roll & backup roll bearing faults
  • Chock alignment drift
  • Gearbox & spindle vibration
  • Lubrication system anomalies

Impact

58 hours of ROT-roll uptime protected. 2022-2026

JSW Steel - the world's most valuable steel company.

Blower AI Shield

High-stakes AI for turbo-blowers and axial compressors feeding blast furnaces. Monitors
surge margins, bearing health, blade condition, and inter-cooler performance 24/7.

Blast Furnace Blowers

Faults Detected

  • Impeller & blade wear
  • Bearing degradation
  • Surge & stall events
  • Inter-cooler fouling & seal leaks

Impact

1 prescription = 12 hours of unplanned blast-furnace downtime avoided.

~$2.0M* in production protected at JSW by a single call on the ID fan.
*Production-protected values are conservative estimates, combining industry-standard downtime benchmarks with validated Infinite Uptime prescription data.

Cement

Cement Solutions

Kiln uptime is your cost of goods. We protect it.

Kiln AI Shield

Purpose-built AI for rotary kiln reliability. Monitors bearing temperatures, tyre & roller wear,
shell deformation, and combustion anomalies — delivering prescriptions 14–21 days before failure.

Rotary Kilns

Faults Detected

  • Bearing degradation & overheating
  • Tyre & roller misalignment
  • Shell ovality & hot spots
  • Burner & combustion drift

Impact

45 hours of kiln uptime protected.

April–May 2026, at the world's 3rd largest cement producer. Two months. One asset. Zero guesswork.

Mill AI Shield

End-to-end VRM health monitoring covering grinding pressure, vibration signatures,
separator performance, and gearbox faults. Reduces unplanned stops and extends mill life.

Vertical Roller Mills

Faults Detected

  • Gearbox mesh & lubrication faults
  • Roller & table wear
  • Fan imbalance & bearing failure
  • Separator drive anomalies

Impact

1 prescription = 48 hours of VRM downtime avoided.

Spotted early gear wear in the gearbox — before it could halt the mill. At one of the world's largest cement producers.

Tire & Rubber

Tire & Rubber Solutions

Mixing and extrusion uptime drives your throughput.

Mixer AI Shield

Dedicated AI for Banbury internal mixers covering rotor health, gearbox condition, ram & door
seals, and batch-to-batch process consistency. Prevents costly compound quality failures.

Banbury Mixers

Faults Detected

  • Rotor imbalance & bearing wear
  • Gearbox helical & bevel faults
  • Ram cylinder seal degradation
  • Motor harmonics & thermal drift

Impact

1 prescription = 22 hours of unplanned Banbury-mixer downtime avoided.

~$650K* in production protected at CEAT— off a single gearbox call.
*Production-protected values are conservative estimates, combining industry-standard downtime benchmarks with validated Infinite Uptime prescription data.

Extrude AI Shield

Process and mechanical AI for rubber extrusion lines. Monitors screw & barrel wear, die pressure
consistency, drive faults, and temperature uniformity to protect output quality and machine life.

Extruders

Faults Detected

  • Screw & barrel wear profiles
  • Drive motor & gearbox faults
  • Die pressure & temperature anomalies
  • Feed roll bearing degradation

Impact

98 hours of extruder uptime protected. 2024-2026

MRF — India's largest tyre manufacturer.

Pulp & Paper

Pulp & Paper Solutions

Maximize roll and press uptime, prevent web breaks.

Dryer AI Shield

Process and mechanical AI for paper machine dryer sections. Monitors cylinder & felt roll bearings,
drive train integrity, thermal stress, and roll surface condition to protect sheet quality and machine life.

Dryer Sections

Faults Detected

  • Cylinder & felt roll bearing failure
  • Drive shaft shear & connecting gear damage
  • Roll shell wear & thermal fatigue
  • Cylinder imbalance & oil contamination

Impact

235 hours of Dryer uptime protected. 2022-2026

Across all Paper Customers.

Metals & Mining

Metals & Mining Solutions

Heavy-duty AI for crushers, mills, and material handling.

Vibro-Screen AI Shield

Process and mechanical AI for vibratory screens and feeders. Monitors bearing & drive condition, structural
and weld integrity, vibration dynamics, and screen surface wear to protect screening quality and machine life.

Vibratory Screens & Feeders

Faults Detected

  • Bearing failure & shaft shear
  • Structural integrity & weld cracks
  • Side plate failure & thermal fatigue
  • Weight unbalance, resonance & screen tear

Impact

1 prescription = 30 hours of unplanned downtime avoided.

~$450K* in production protected at one of Asia’s leading mining enterprises — triggered by a single, critical exciter-bearing call.
*Production-protected values are conservative estimates, combining industry-standard downtime benchmarks with validated Infinite Uptime prescription data.

Plant Fusion

Plant Fusion

Cross-Vertical Solutions

AI Shield for Every Critical Asset

Plant Fusion turns condition and process intelligence into the three decisions that run a plant — maintain,
stock, invest. One risk foundation (failure probability, consequence,MTBF, lead time, criticality) feeds
all three, so they aren't three tools — they're one decision layer. Risk-first, governed, traceable.

Plant-wide risk, shielded.

Faults Detected

  • Maintain — dynamic, ISO-aligned PM program that runs RBI, RCM, and FMEA per failure mode, not a fixed calendar
  • Stock — risk-aligned min/max and ordering triggers; safety-critical items always human-gated
  • Invest — CAPEX backed by failure-probability forecasts and remaining-life estimates
  • See — cross-asset risk linked to throughput, energy, and OEE that no single monitor flags

Impact

1 risk model, 3 decisions

Spares, maintenance, and CAPEX focused where actual risk lies. 15–25% PM cost reduction · 20–40% emergency purchase reduction · zero stockouts of RUL-tracked parts

02

Critical Equipment Reliability

Critical Equipment Reliability is continuous, always-on monitoring for the assets that stop production when they stop. It uses wired piezoelectric accelerometers, which capture the widest frequency band at the highest resolution and stream without interruption. That fidelity is what catches early-stage bearing, gear and lubrication faults, & more before they propagate.

Sensing Technology
Wired Piezoelectric

Piezoelectric accelerometers capture the widest frequency band at the highest resolution. Hard-wiring means uninterrupted streaming, with no power or data gaps.

150 °C surface 2 RPM Harsh environments
9 verticals
Explore Critical Equipment Reliability
03

Standard Equipment Reliability

Standard Equipment Reliability covers the general rotating equipment across your plant: pumps, fans, motors, gearboxes, compressors, & more. It runs on MEMS sensors, and can be deployed them wired where you already have infrastructure and wireless where you do not, with the same coverage either way.

Sensing Technology
Wired or Wireless MEMS

Micro-Electro-Mechanical Systems (MEMS) deliver broadband vibration data at a fraction of the install cost and footprint.

Flexible deployment Fast install
9 verticals
Explore Standard Equipment Reliability
04

Non-critical Equipment Monitoring

Non-Critical Equipment Monitoring brings the balance of plant into view, the everyday equipment that has never justified a monitoring budget. A plant team can self-install them in minutes and scale across hundreds of assets.

Sensing Technology
Self-Powered Wireless - Infisense 3XT

Infisense 3XT sensors run on harvested light energy, with no gateways, no cabling and no electrical budget. One can scale across the balance of plant equipment without drawing plant power or running new conduit.

BOP equipment Self-Powered Wireless Quick Install · no gateways
9 verticals
Explore Non-Critical Equipment Monitoring
Budget Quote · BOP Monitoring

Size your BOP monitoring budget

Take Balance of Plant monitoring off manual rounds — and onto sensors that watch every piece of equipment for you.

3,000 assets
1,000MOQ 3,000volume rate 5,000+
Estimated annual budget Volume rate applied
$21,000
3,000 sensors · Hardware only · VAT excluded
12,000 manual inspection hours replaced each year
365 days a year each asset is watched automatically — not 12 manual rounds

Indicative estimate only, for master-distributor volumes. PlantOS™ subscription and deployment are quoted separately. Manual inspection hours are benchmarked at ~4 hrs / asset / year. Final commercial quotation confirmed by our team.

Whole-Plant Coverage, From the Critical Few to the Everyday Many

No blind spots. Critical Equipment Reliability, Standard Equipment Reliability and Non-Critical Equipment Monitoring span the full criticality spectrum, so every machine on your floor feeds one unified picture of plant health.

Compounding Intelligence

Why does the outcome gap widen instead of closing?

Zero Guesswork. Compounding Intelligence. Starts Day 1.

Infinite Uptime retraining across 946 plants
Horizontal platforms static local models drift over time

The Structural Cause

Compounding intelligence through the 99% Trust Loop

PlantOS™ - the Prescriptive Al that learns continually across the entire installed base. Operator validation turns every correction into shared intelligence, so each asset teaches every other. Horizontal platforms rely on static local models that drift over time. Because PlantOS™ retrains across 946 plants, drift is caught before it compounds, and accuracy improves the longer the system runs.

IMPLEMENTATION

How long does it take to
deploy PlantOS™ Prescriptive AI?

The Path to Reliability Outcomes Your Operators Trust - in 90 Days

No rip-and-replace works with your existing systems.
First prescription in 2 weeks. Scale with confidence.

Week 1-2

Solution Deployment

  • 100% equipment coverage Day 1
  • Rotating + static equipment + process context
  • Baseline assessment complete

Week 3-4

First Prescription

  • Operator validation workshop
  • Digital signoff trained
  • First fault prescribed

Month 2

Scale & Optimize

  • Additional equipment lines
  • Process efficiency modules
  • KPI baseline established

Month 3

Plant-Wide

  • Board-ready ROI report
  • Expansion planning
  • 99% Trust Loop complete

Ready to see your first prescription?

Book a discovery call. We'll model your specific equipment risk and ROI before you commit.

Try PlantOS™

Frequently Asked Questions

01 What is prescriptive maintenance and how is it different from predictive maintenance?

Predictive maintenance forecasts that a machine is likely to fail and roughly when. Prescriptive maintenance goes further: it identifies the specific component at fault mapping both mechanical and process-induced faults, prescribes the corrective action, and highlights the guaranteed outcomes. PlantOS™ then captures whether the fix worked, so its recommendations improve with every validated outcome.

02 What is Dynamic FMEA in prescriptive maintenance?

Dynamic FMEA is the method behind Al Shields. A traditional Failure Modes and Effects Analysis is a static document, written once and quickly outdated. Dynamic FMEA continuously correlates live mechanical signals with real process conditions, so it detects failure modes that appear only when heat, load or chemistry change. That is how PlantOS™ identifies faults such as thermal fatigue and cyclone jamming that generic vibration monitoring cannot see.

03 Does Infinite Uptime's solution require replacing existing equipment?

No. PlantOS™ requires no rip-and-replace. Sensors are retrofitted onto your existing equipment and PlantOS™ works alongside the systems you already run. Most plants receive their first prescription within two weeks of installation.

04 What equipment does the Al Shield Prescriptive Maintenance Solution support?

AI Shields are built for flagship heavy industrial equipment, specifically kilns, mills, cranes, furnaces, dryers, etc. Each Shield is trained on the failure signatures of that exact equipment class and detects both mechanical and process-induced faults including thermal fatigue, material build-up, cyclone jamming, oil contamination, gear-mesh backlash, and more.

05 Which PlantOS™ solution is right for my equipment?

It depends on criticality. Al Shields cover flagship equipment such as kilns, mills, cranes and furnaces. Critical Equipment Reliability covers the assets that stop production when they stop, using wired piezoelectric sensors. Standard Equipment Reliability covers general rotating equipment, wired or wireless. Non-Critical Equipment Monitoring covers the balance of plant using self-powered wireless sensors. Together they span the full criticality spectrum.