PlantPulse delivers vendor-neutral air compressor monitoring across your entire compressed air system — every rotary screw, reciprocating, and centrifugal unit in one dashboard, no matter who manufactured it. Instead of logging into three separate OEM portals, your team watches vibration, temperature, and power signatures for the whole air room from a single pane of glass.
Compressed air is one of the most expensive utilities in any plant, and 20–30% of it is typically lost to leaks and over-pressurization. Continuous condition monitoring quantifies that waste while predicting the airend, motor, and bearing failures that take a line down — at roughly $200 a minute of downtime — so you fix problems on your schedule, not the compressor’s.
Because PlantPulse retrofits any unit over cellular in a single day, you get air compressor predictive maintenance without replacing equipment, wiring into a PLC, or waiting on IT.
What we monitor on your air compressors
The signals that predict airend failure and reveal hidden energy waste.
Airend vibration
High-frequency vibration and bearing signatures that flag a failing airend weeks before it grenades.
Discharge & oil temperature
Climbing temperatures that signal cooling, lubrication, or load problems early.
Motor power & amp draw
A 10–15% creep in amp draw is an early warning of mechanical or efficiency loss.
System pressure & energy
Continuous pressure and energy tracking that surfaces leaks, short-cycling, and over-pressurization.
Failures we catch early
The developing faults behind most unplanned compressor downtime.
Airend & bearing failure
The most expensive failure mode, predicted weeks out from rising vibration and temperature.
Motor degradation
Amp-draw and vibration trends that flag winding and bearing problems before a burnout.
Energy waste & leaks
The invisible 20–30% lost to leaks and over-pressurization, quantified continuously.
Cooling & lubrication issues
Temperature drift that precedes overheating shutdowns and accelerated wear.
Why plants choose PlantPulse for compressed air
One vendor-neutral dashboard for a mixed-brand air room.
Same-day cellular install
Sensors mount directly on your air compressors and stream over cellular the same day — no SCADA tie-in, no plant network, no IT tickets, no capital project.
Every brand, one dashboard
Atlas Copco, Ingersoll Rand, Kaeser, Sullair and more in a single view — no OEM lock-in, no separate logins.
AI insights in plain language
Our AI models watch vibration, temperature, and pressure trends and tell your team what is failing and roughly when — not just another alarm to triage.
Energy visibility
Continuous power monitoring turns compressed-air waste from a guess into a number you can act on.
Aligned with DOE & ISO best practice
We build on the product-neutral standards that define compressed-air efficiency and reliability.
- U.S. DOE & Compressed Air Challenge — Best-practice efficiency guidance (AIRMaster+) that frames how we surface and quantify energy waste.
- ISO 8573-1 & ISO 12500 — Air-purity and filtration standards that matter for food, beverage, and pharma compressed air.
- ISO 20816 / 10816 — Machine-vibration severity standards underpinning our airend and motor alert thresholds.
- ISO 50001 & ENERGY STAR — Energy-management frameworks and utility rebate programs our monitoring data supports.
Built for your line
- Automotive
- Food & beverage
- Plastics & molding
- Packaging
- Metal fabrication
- General manufacturing
Questions operations teams ask
Straight answers on installation, coverage, and compliance.
Does this work on any brand of air compressor?
Yes. PlantPulse is vendor-neutral and monitors Atlas Copco, Ingersoll Rand, Kaeser, Sullair, and others together in one dashboard.
Do I have to replace or modify my compressor?
No. Clamp-on cellular sensors retrofit to existing units with no PLC or SCADA tie-in and no equipment replacement.
How does it predict an airend failure?
Rising vibration and high-frequency bearing signatures, climbing discharge temperature, and a 10–15% amp-draw creep flag failures weeks ahead of a breakdown.
How long does installation take?
Same day. Sensors stream over cellular with no IT involvement, network changes, or downtime.
Can it find compressed-air energy waste?
Yes. Continuous power and pressure monitoring surfaces the 20–30% typically lost to leaks and over-pressurization so you can target it.
Book a same-day air-room assessment
Tell us how many compressors you run and which brands, and we will put your whole air room on one dashboard.