Compressed air is a key energy source in industrial production. Compressors supply machines and tools with the necessary power, but generating this energy is both costly and energy-intensive. For reliable operation, compressed air must be provided efficiently, dry, and clean. In many cases, there is also no central monitoring or data-based maintenance planning in place.
With SMARTmodbus from PSsystec, this can change. The IoT solution package creates transparency, reduces energy consumption, and paves the way for predictive maintenance.
The challenge: High energy demand and lack of transparency
In many facilities, compressed air systems form part of the central energy supply. They power machines, tools, and equipment, from simple screwdrivers to industrial milling machines. However, generating this energy is expensive: around 10 to 15% of industrial electricity consumption is used for compressed air production alone.
A significant portion of that energy is lost. Leaking pipes, inefficient compressor operating times, or outdated controls cause air leaks, pressure losses, and unnecessary load peaks. These issues often go unnoticed because systems are typically not continuously monitored and no transparent data basis on efficiency or condition exists.
In addition, the heterogeneity of the equipment—different manufacturers, controls, and interfaces—makes it difficult to evaluate operating data collectively. A central IT connection is rarely available or requires considerable effort.
All of this leads to several challenges:
- High energy consumption due to leaks and inefficient operating modes
- Lack of real-time data and transparency regarding conditions and consumption
- Increased maintenance effort, as malfunctions are often only noticed after a failure
- Diverse system environments that prevent unified monitoring
- Cost pressure and increasing demands for energy efficiency
Moreover, many companies face pressure to modernize. Existing compressors need to be digitalized during ongoing operations, without costly new purchases or production interruptions.
This is exactly where PSsystec’s SMARTmodbus solution comes in—a retrofittable, standardized, and secure IoT infrastructure for industrial energy management.
The solution: SMARTmodbus connects compressors to the cloud
The SMARTmodbus solution package developed by PSsystec forms the foundation for efficient remote monitoring and analysis of compressed air systems.
The central hardware component is the SMARTbox mini, a compact IoT gateway for connecting Modbus devices in industrial environments. The SMARTbox mini uses modern IoT cloud platforms such as Cumulocity and Telekom Cloud of Things. Depending on the variant (RTU, TCP, or Outdoor), it offers either a wired or wireless connection via LTE, NB-IoT, or 2G. The outdoor version features a plastic housing with IP65 protection, while the control cabinet version (IP24) comes with an aluminum enclosure.
Using the Modbus protocol, up to 32 slaves with a maximum of 400 data points can be connected—manufacturer-independent and without the need for on-site setup.
Configuration of the Modbus registers and the entire network management is handled remotely via a device management platform such as Cumulocity IoT, with over-the-air updates and integrated security patches.
The system allows both read and write access to all connected devices. Typical measured variables include pressure, temperature, dew point, flow rate, operating hours, and leakage alerts. Through a REST API, all data, events, alarms, and commands are also available for customer systems.
Secure data transmission is ensured by the PSA-certified digitalization process, from the gateway level through the mobile network all the way to the cloud.
Key features of the SMARTmodbus solution:
- Real-time data analysis for early fault detection
- AI-supported automatic fault diagnostics
- Intuitive user interface for monitoring and reporting
- Easy integration into existing systems
- Scalable for additional lines and locations
- Automatic notifications in case of deviations
The result: Energy efficiency, operational reliability, and predictable maintenance
Implementing the SMARTmodbus solution creates an entirely new level of transparency in compressed air supply systems. Users can monitor the condition and efficiency of their compressors in real time, including all relevant measurements and alarm notifications. This makes it possible to detect leaks and anomalies early, before they lead to energy losses or downtime.
Continuous data collection also enables predictive maintenance planning. Service operations are no longer based on rigid intervals but on actual operating data. This reduces downtime, extends equipment lifespan, and lowers maintenance costs.
Operators and distributors of industrial equipment also benefit from the ability to monitor customer systems remotely, diagnose malfunctions from a distance, and proactively offer maintenance services.
Another advantage: thanks to standardized interfaces and retrofit capability, SMARTmodbus can be integrated into existing systems without interfering with ongoing production.
Results at a glance:
- Early detection of leaks and inefficiencies
- Reduced energy consumption and improved operational reliability
- Remote access and real-time alerting
- Predictable maintenance instead of unplanned downtime
- Retrofit-capable, scalable, and manufacturer-independent
