• Increase availability and reliability
  • Reduce unplanned downtime
  • Greater understanding of equipment conditions
  • Reduce OPEX
  • Peace of mind and stress-free maintenance planning

No more unplanned downtime

With equipment in continuous use, damage can happen at any time. While visual inspections are important to provide broad, contextualised operational insights, relying only on intermittent site visits puts you at risk of missing the early warning signs that could enable you to drastically reduce both downtime and expenses. Online condition monitoring is a continuous service that enables you to detect potential failures well in advance, giving you plenty of time to take preventative action and avoid actual failure.

Online condition monitoring flowsheet
How can you achieve optimum maintenance?​ Data + Technology + Expertise

Early detection, swift action

Wear. Misalignment. Excessive vibrations. All these symptoms warn you that damage is imminent. In many cases, when the visible symptoms appear, it is already much too late for an ‘easy’ fix. By contrast, sensors on your equipment are able to capture data that may be otherwise ‘invisible. Our online condition monitoring services connect this data to the cloud where it is continuously monitored and trended. If something is wrong, an alarm notifies our team of experts who are able to analyse the data remotely and develop a recommended action plan to rectify the fault well ahead of it escalating. It’s a low-stress, low-cost, low-risk approach to maintenance that offers high returns. 


More than just data

The value of online condition monitoring services is not only in the data that’s gathered – it’s in the interpretation of that data by our experts. We use our plant and technology experiences to add context to the numbers, assessing what is meaningful and what requires action and returning those insights to you in  practical recommendations.

We offer human expertise, powered by technology

We leverage our 138 years of product and process knowledge through digital technology and onsite visits, to ensure that our customers get the best service, at the right time and in a simple manner.

This knowledge is based upon 2300 assets connected worldwide, 20 years of remote support to our customers and 8 years of online condition monitoring experience.

Taking advantage of evolving technology

Industry 4.0 is here, and many plant assets are already connected. We are continuously working on new ideas and solutions to take advantage of all the potential offered by the Internet of Things (IoT). Online condition monitoring services offer incredible possibilities to enhance equipment efficiency, reduce operating costs, eliminate unplanned downtime and run a more sustainable operation.

Already, we have online condition monitoring service solutions for the following assets:
FLSmidth Digitalisation

ECS/ControlCenter™ Platform

If your control system goes down, your productivity is immediately impacted. You simply can’t run the plant without it. And all the while you are shutdown, the costs mount up.

Our online condition monitoring services for the ECS/ControlCenter Process Control Software Platform ensure this doesn’t happen. We continuously monitor all your key equipment to ensure everything is working optimally. Our specially designed algorithm automatically detects any abnormalities that may impact the performance of ECS/ControlCenter and alerts our 24/7 Global Remote Service Centre, who will make recommendations or – if needed – work with you to fix the problem. 

Kiln for cement plant


Kiln downtime affects the entire cement plant. With our online condition monitoring services for kilns, you can gather insights and data that was previously unavailable – and identify the root cause of typical kiln problems. Monitor. Act. Optimise.  

Vertical Roller Mills

When it comes to your VRM, you have certain expectations: reliable, consistent performance; expected capacity, and optimum energy efficiency. But realising those expectations is dependent on achieving the right operating parameters, the best mechanical settings and ensuring the good condition of critical components. Even the smallest failure in any of those areas can have dramatic consequences. Our online condition monitoring services enable you to keep a constant eye on those focus areas so that you can make the adjustments needed to ensure that the mill performs to its maximum potential. 

Gear unit

No one wants to experience gear failure. Apart from the expense, the repair time can be extensive. Our Predicta online condition monitoring service helps extend gear life and reduce unplanned downtime, enabling you to be strategic with your maintenance plans. By identifying issues early, you have time to act before failure occurs, allowing you to prepare for maintenance stops, source parts and generally make sound decisions that are based on reliable, insightful data. Lower TCO, lower stress, longer gear life.

Air pollution control

Filter bag performance determines how effective your air pollution control program can be. It’s not something you want to leave to the occasional visual inspection.

AFT® SmartLife, our online condition monitoring solution for filter bags, enables you to be more strategic, tracking filter bag wear so that you know not only where failure is likely to strike but also which operating parameters may be contributing to excessive wear. Act fast. Remain compliant.

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