Motor Circuit Analysis: A Powerful Predictive Maintenance Technique

Motor circuit analysis (MCA) is an essential predictive maintenance technique utilized by equipment performance monitoring services to assess the condition of critical rotating machinery. By performing a comprehensive series of electrical tests, MCA provides in-depth diagnostic data about the operating health and performance of motors, generators, servomotors and other electro-mechanical assets.


This powerful analysis method allows for early detection of developing faults like insulation degradation, voltage imbalances, overheating, misalignment and more – often before they lead to major failures or unexpected downtime. For facility operators, implementing MCA as part of a world-class condition monitoring program is invaluable for maximizing asset reliability, availability and productive uptime while minimizing costs and safety risks.

The MCA Diagnostic Process

To assess the electrical condition of a motor or generator, motor circuit analysis evaluates key properties of the equipment’s circuitry including resistance, inductance, capacitance, impedance, phase angles, current/frequency ratio, dissipation factor, and static/dynamic electrical signatures. A typical MCA diagnostic follows this process:


  • With the asset de-energized, take offline electrical tests to establish baseline readings
  • While the equipment is running, perform online current analysis and voltage analysis
  • Analyze the data to identify any anomalies or deviations from established benchmarks


Even subtle changes in these electrical properties can indicate issues like turn-to-turn shorts, ground faults, contamination, loose connections, and other developing faults. By detecting them early through motor circuit analysis, MCA allows the opportunity for remedial actions before catastrophic failures occur.

Applications Across Industries

Motor circuit analysis has applications across numerous industry sectors wherever critical rotating equipment is utilized, such as manufacturing, power generation, oil and gas, mining, utilities, and more. Whether for AC or DC motors, generators, servos or other rotating assets, MCA provides invaluable equipment performance monitoring services.


For these facilities, the key benefits of implementing motor circuit analysis as part of a comprehensive predictive maintenance program include:


  • Improved asset reliability and availability through early fault detection
  • Extended useful operating life by identifying issues before major damage
  • Enhanced workplace safety by mitigating electrical hazards and fire risks
  • Comprehensive equipment condition data even during normal operations
  • Optimized maintenance strategies, production schedules and budgets


By continuously monitoring asset health through techniques like MCA, facilities can transition away from reactive maintenance approaches. This proactive, predictive maintenance strategy increases uptime, reduces costly unexpected breakdowns, and improves overall risk management.


Whether for new installations or aging assets, motor circuit analysis should be a core component of the predictive maintenance program at any facility that relies on rotating machinery. The detailed diagnostic insights it provides about electrical system condition allows maintenance teams to plan repairs during scheduled outages and optimize equipment lifetime performance and reliability.


Motor circuit analysis offers a powerful condition monitoring solution for pinpointing developing faults before they result in downtime events. By leveraging MCA’s in-depth electrical signature analysis as part of equipment performance monitoring services, operators can make data-driven decisions to increase asset availability, productivity and operating safety while minimizing costs and risks.

Why Your Industrial Operation Needs Real-Time Predictive Machine Performance Monitoring

In industrial settings, machines are very important. They do the hard work of manufacturing products and handling automation tasks. But did you know that machines need maintenance too? Just like a car, industrial machines can break down if not taken care of properly through routine maintenance and real-time monitoring.


Predictive maintenance is a smart way to keep machines running smoothly. It uses special machine performance monitoring services, wireless sensors, and software to check on machine performance. These services watch for any problems before they lead to malfunctioning and then failure. That way, maintenance can be done at the right time to prevent bigger issues.


This blog post explains why predictive maintenance through machine monitoring is so valuable. We’ll cover the major advantages it provides industries across sectors.

Real-Time Tracking

One key advantage of industrial monitoring solutions is real-time tracking. Special sensors are placed on machines to constantly measure things like temperature, vibration, pressure and more. The machine data is monitored by software that looks for any unusual readings.


For example, say a machine’s vibration levels get too high. That could mean a bearing is going abnormal and needs replacement soon before it causes the machine to break down.


The real-time monitoring alerts the team when readings go outside the normal ranges. This allows them to inspect the machine and fix small issues before they turn into expensive maintenance!

Workflow Improvements

Over 80% of companies have faced unplanned downtime due to machine failures in recent years. Downtime is very costly and disruptive to workflows.


Industrial monitoring solutions help optimize workflows by predicting machinery issues ahead of time. This allows maintenance to be scheduled during already-planned stoppages rather than unexpected breakdowns.


Let’s look at a cement mill for example. These big mills grind rock into the powder that becomes cement. A monitoring system tracks things like the mill’s motor current, vibration, temperature, material flow, and more.


If motor current starts rising abnormally, it may signal a blockage or mechanical fault. Without monitoring, this could burn out the motor and cause a fire hazard! But the system alerts teams to check on the issue before an emergency shutdown is required.


With predictive insights, cement makers can schedule the perfect time for maintenance that avoids disrupting the entire workflow. This maximizes productivity and efficiency.

Improved Safety

Another key benefit of machine performance monitoring services is improved workplace safety. Monitoring helps stop dangerous situations before they can occur.


For example, if a motor’s temperature readings are too high, it could mean lubrication problems that lead to overheating and fire risks. The early alerts give teams a chance to shut it down and fix the issues safely.


Real-Time Monitoring also reduces the need for major repairs by catching small faults early. This minimizes situations where technicians have to make complex, high-risk repairs under time pressure before serious failures happen.


In simple words, real-time machine performance monitoring helps keep both equipment and people safe throughout manufacturing facilities.

Higher Product Quality

Nobody wants to buy low-quality or defective products. That’s why monitoring machine performance is so important for quality control.


Monitoring systems integrate with quality systems to capture data from all machines and sensors. By analyzing this data, they can identify any machine faults or deviations that could lead to quality issues in the final products.


Let’s say a plastic injection molding machine’s temperature is reading too low. This means the plastic won’t flow properly, resulting in defective parts. Monitoring software can automatically pause the line and alert quality teams before a whole batch of pool-quality products gets manufactured.


With this level of monitoring, manufacturers can ensure consistent high quality by immediately addressing anything that could negatively impact production quality.

Better Equipment Reliability

Monitoring also contributes to overall better reliability for all manufacturing machinery and assets. It enables true condition-based predictive maintenance.


Instead of routine maintenance at fixed intervals, which may be too soon or too late, monitoring data reveals the precise condition of each machine. This way, maintenance gets scheduled only when actually required based on equipment health.


For example, analyzing bearing vibration trends predicts when replacements are needed. The right spares and labor can be prepared to swap out the failing bearings during a scheduled downtime window. No unexpected breakdowns!


This condition-based approach ensures maintenance actions directly target the areas that need attention most. It eliminates unnecessary maintenance while also preventing untimely failures. The result is maximum reliability, uptime, and asset lifespan for all machines.


In summary, deploying machine performance monitoring services provides manufacturing companies incredible value through:


  • Real-time machine health tracking
  • Optimized maintenance workflows
  • Improved workplace safety
  • Consistent high product quality
  • Maximum equipment reliability and uptime


With all these benefits, predictive maintenance through industrial monitoring solutions is an absolute must-have for any modern manufacturing operation.


Don’t let unexpected machine failures, unplanned downtime, quality issues, and safety risks plague your facility. Stay one step ahead by investing in a proven machine monitoring platform today. Your operations, maintenance teams, and entire business will thrive!

Introducing Our Dynamic Partnership: Transforming Laser Shaft Alignment with HAMAR

We are thrilled to announce a game-changing collaboration redefining Laser Shaft Alignment in the southern United States.


SEMEQ SYSTEMS and HAMAR LASER, renowned for their top-notch products like the X-Series™ Laser Shaft Alignment, have joined forces. As authorized distributors of Hamar Laser in Texas, Oklahoma, Louisiana, Arkansas, Missouri, and Iowa states, we are excited to bring you the best-in-class X-Series™ Laser Shaft Alignment products, known for their unwavering reliability and performance.


Our quest to expand and capture market share in the region led us to seek a partner who shares our vision for innovation and brings unique strengths and expertise;  we found the ideal match – a company with a diverse clientele and a proven history of delivering exceptional solutions in HAMAR LASER.




For over 55 years, Hamar Laser Instruments has pioneered laser alignment, with 34 years dedicated to shaft alignment applications. The company aims to enhance asset availability, drive customers’ profitability, and reduce operational costs. Hamar Laser is committed to innovation and clients’ success and delivers cutting-edge solutions that empower customers to thrive.




Discover the Innovation Behind Unidirectional Dual-Beam™ and Dual-Fan™ Technology


The X-Series™ Laser Shaft Alignment products are designed with your ease of use in mind. Our Hamar software has undergone rigorous development to ensure user-friendliness, requiring minimal training even for complex applications. We aim for simplicity that instills confidence and comfort in our users, making the technology feel like second nature.


Safety Features in the X-Series™


The X-Series™ is designed with your safety in mind, and it incorporates multiple safety features, including rugged IP65 Windows® tablets and IP67 laser heads and targets suitable for harsh environments. Bluetooth® technology enables wireless communication between the tablet, laser, and target, enhancing safety around rotating equipment. Small-diameter laser beams and narrow-line laser fans maximize the PSD sensor measuring range, enhancing safety compared to competitors’ more comprehensive laser lines. With these safety features, you can feel confident and secure about the operation of the X-Series™.


Advantages of Laser Alignment Systems Over Indicators


The X-Series™ Laser Shaft Alignment products offer advantages over traditional methods like dial indicators. Determining the rotation axis of one shaft relative to another in shaft alignment is crucial for eliminating misalignment. Conventional methods could be more convenient, precise, and time-consuming, requiring interpolation of readings, compensation for bracket sag, and manual calculations, complicating the process. The X-Series™ Lasers streamline alignment by recording position and angular data using the software while rotating the laser and target, capturing up to 16 points/second. This method calculates and subtracts mounting errors from the raw data, providing highly accurate alignment without manual calculations and offering a hassle-free experience.


Unlocking Enhanced Precision and Flexibility with Dual-Beam™ Detector Technology


Our patented Dual-Beam™ technology is a game-changer in laser alignment systems. It allows for simultaneous measurement of offset and angle with just one PSD, boosting system accuracy by an impressive 50%. We conduct a meticulous 500-point calibration on the PSD, setting a new industry standard for accuracy that surpasses competitors’ systems by up to 15 times. With this level of precision and accuracy, you can trust the performance of our Dual-Beam™ technology.



But the innovation continues beyond there. With Dual-Beam™ technology, you gain an extraordinary angular range of +/- 12 degrees, ensuring consistent laser targeting even in long-distance applications. Plus, our angular resolution surpasses the highest angular tolerance by a factor of 10, guaranteeing unmatched precision in alignment processes.


Our blinking laser technology seamlessly compensates for ambient light variations to elevate performance further, ensuring reliable measurements regardless of environmental conditions.



Outperforming Competitor’s Mid-Range Systems: Introducing Entry-Level Dual-Fan™ Detector Technology


Our Dual-Fan™ technology redefines entry-level shaft alignment systems, delivering unmatched economy, versatility, and accuracy. With Dual-Fan™, you can achieve exact measurements of offset and angularity simultaneously, thanks to two 0.5-degree laser fans and two 20 mm PSDs.



Unlike competitors’ lasers, which pose safety concerns with wider fan spreads, our specially designed laser fan extends only to 1 inch (25.4 mm) at 15 feet (4.6 m), ensuring safer operation without compromising accuracy.


Moreover, Dual-Fan™ offers a full angular measuring range across the entire operating distance between the laser and the target. This eliminates the limitations of the “cross-fire” lasers face, which experience restricted angular measuring ranges beyond 3 feet (and 1 m). Conducts a meticulous 40-point calibration procedure on the P to further enhance accuracy, making our Dual-Fan™ technology up to 5 times more precise than competing mid-priced systems. Blinking laser-fan technology also compensates for ambient light, guaranteeing consistent environmental performance.



Durable, Sealed IP67 Casings


All X-Series™ alignment hardware “heads” are compact, sturdy, and engineered to swiftly and effortlessly deliver precise, reliable alignment data. They boast an IP67 rating for waterproofing (submersible up to 3 feet or 1 meter), ensuring durability in harsh conditions. Our handheld display units feature high-resolution, color touchscreens. Unlike competitors, our wireless transmitter is securely enclosed within the heads, eliminating the risk of connector or cable failure.



Embedded Technology


We prioritized user-friendly design, integrating “smart” LEDs for intuitive laser status indication at a glance.


Intuitive Software for Seamless Alignment


Our Couple6 software is as intelligent as our hardware, featuring Easy-Guide™ navigation with vibrant color screens that guide users effortlessly through each alignment step. Even beginners can achieve expert-level results with our 5-step process, culminating in easy report generation.



Revolutionary Live Move Screen for Precision Shaft Alignment


Introducing Duo-Plane™ Live Move screen, an innovative feature on the T-1290 5-Axis Target. Unlike traditional systems, Duo-Plane™ allows users to view vertical and horizontal alignment screens simultaneously, eliminating the need to rotate shafts. This groundbreaking technology saves valuable time, particularly on large machine applications where bolt tightening can cause machine movement, necessitating realignment.



In our X-660 and X-770 3-axis systems, we introduce an intuitive 2-axis “live” display feature. This dynamic display showcases continuously updating graphics, clearly illustrating motor alignment along the horizontal or vertical axis. Simply rotate the shafts from 12:00 to 3:00 or 9:00 to activate the horizontal axis live move screen. The Couple6 system seamlessly transitions to display alignment results, allowing you to adjust the motor position without the need to reacquire data.



Effortless Precision with Extended PSD Measuring Area


Experience the convenience of our large 20-33 mm PSD measuring areas integrated into our target heads. Coupled with our uni-directional laser beams and an impressive +/- 8 to +/-12 degrees of angular range, you can bypass the time-consuming “rough” alignment process typically required during new machine installations. This translates to significant savings in labor hours each month! Simply attach the laser and target to the shafts and proceed to our Step 2 Laser Setup Screen, where you’ll find a live display of the angular alignment. Rotate the shafts, and you’re ready to capture data if you achieve readings for at least 90 degrees. If not, utilize the live display to roughly align the motor angle for data collection. It’s that straightforward!



Instant Support with On-Demand Training Resources


Always feel safe again with our comprehensive training resources available at your fingertips. Access our electronic manual directly within our Couple6 software by selecting the Help Menu or hitting F1. The correct page of the manual will automatically display, providing quick assistance whenever needed. Watch our on-demand training videos for a quick recap of any procedure. Compare this seamless support experience to our competitors’ cumbersome multi-page cheat sheets or lengthy manuals. With our intuitive software, training is primarily needed for more complex applications, ensuring efficient and hassle-free operation.



No Worries with Off-the-Shelf Software Display


With the X Series, you get the convenience of Windows 10 IoT Enterprise IP65 rugged tablets, available at most computer stores. Say goodbye to costly, proprietary display devices – if your tablet breaks, replacements are easily sourced.



Seamless Upgrade to Advanced Features


Upgrade your entry-level laser system to unlock advanced features effortlessly. Simply send your distributor or us a purchase order for the desired features, and within a day, you will receive a new license via email. Installation takes seconds, and voilà – the new features are ready to use in our Couple6 software!



Printing Reports Made Simple


With our tablets and PCs, printing detailed, customizable color reports is a breeze. Just plug the report into a printer and hit print. Need to email a report? No sweat! Select PDF in the print screen, attach the report to your email, and send it off. Easy as pie!


Continuous Software Updates at No Cost


We believe in constantly enhancing our software to serve our customers better. That’s why we provide free updates for life. With just a click on “Check for Updates,” Couple6 takes care of the rest.



The Advantage of Unidirectional Dual-Beam™ and Dual-Fan™ Technology for Long Spans


Long-distance applications pose challenges for traditional 2-laser/2-detector shaft systems. Even tiny angular movements can significantly affect readings, making alignment difficult, especially for the horizontal axis. Our uni-directional laser technology eliminates this problem. Unlike traditional systems, angular moves to the motor don’t impact the laser beam or offset values. This makes motor alignment remarkably easy, particularly over long distances.



Enhancing Equipment Reliability: a comprehensive guide

Maintaining equipment reliability is paramount to operational success in today’s industrial landscape. With the advent of technologies, companies can now access many tools and strategies to optimize equipment performance and minimize downtime. Let’s delve into some key components of effective equipment maintenance management and explore innovative solutions:

Machine Maintenance Software

Streamline your maintenance operations with a cutting-edge machine maintenance system. These platforms offer robust features such as scheduling, work order management, and asset tracking, enabling you to stay organized and proactive in your maintenance efforts.

Predictive and Prescriptive Maintenance

Say goodbye to reactive maintenance approaches and embrace predictive and prescriptive maintenance techniques. By harnessing the power of data analytics and machine learning algorithms, you can anticipate potential equipment failures and take proactive measures to prevent them, ultimately saving time and resources.

Sensors and Condition Monitoring

Equip your machinery with advanced sensors for real-time condition monitoring. Whether it’s vibration analysis, motor circuit analysis, or acoustics issuance analysis, these sensors provide invaluable insights into your equipment’s health and performance. They allow you to detect and address anomalies before they escalate into costly issues.

Lubrication Engineering

Effective lubrication engineering practices optimize equipment performance and prolong lifespan. Proper lubrication reduces friction and wear and helps dissipate heat and contaminants, ensuring smooth operation and minimal downtime.

Temperature and Humidity Sensors

Invest in heavy-duty temperature and high-accuracy humidity sensors for precise electrical control panels. Whether operating in extreme or sensitive environments, these sensors provide reliable data to help you maintain optimal working conditions and prevent equipment damage.

Industrial Monitoring Solutions

Leverage industrial monitoring solutions tailored to your specific needs. From comprehensive equipment performance monitoring services to high-temperature applications with sensor monitoring, these solutions offer customizable features to meet the unique challenges of your industry.

By integrating these tools and strategies into your equipment maintenance management framework, you can enhance reliability, minimize downtime, and unlock new levels of efficiency in your operations. Embrace innovation and stay ahead of the curve in today’s competitive landscape with SEMEQ.

7 benefits of wireless sensors in predictive maintenance

Industry 4.0 combines various digital innovations and technologies, such as the Internet of Things and artificial intelligence, which can revolutionize industrial operations.

Today, the wireless sensor is one of the most widely used technologies in predictive maintenance. This device provides more accurate results on the state of the equipment since it has a very high sensitivity for detecting anomalous minimum vibrations. It can also be monitored online, even in industrial parks far from major centers.

If you still doubt the effectiveness of these devices, here are 7 benefits of wireless sensors in predictive maintenance.

1. Greater efficiency in production processes

Through process simplification and enhanced data accessibility, wireless sensors empower industrial parks to optimize productivity and minimize resource utilization on the factory floor.

According to Senai’s research, Industry 4.0’s digital technologies can increase the productivity of micro, small, and medium-sized companies by an average of 22%.

Industry 4.0, with its reliance on wireless sensors, significantly reduces maintenance and labor costs, allowing manufacturers to enhance productivity, quality, and revenue growth.

2. Safer, data-based decision-making

The benefits of the wireless sensor in predictive monitoring are significant. Using artificial intelligence technologies, a large volume of data can be collected to generate valuable insights for the operation of industrial parks.

Some examples are the performance of each piece of equipment, the useful life, the availability and reliability of each industrial plant, and the production potential of each park.

This data is collected using big data & analytics resources and read by professionals in predictive monitoring.

3. Savings on repairs and downtime

One of the main benefits of the wireless sensor in predictive maintenance is the regular checking of assets in advance, thus avoiding unexpected problems with repair maintenance.

In addition, because it is a wireless sensor, it is possible to save on cabling and labor for data capture since the process is automated.

4. Ease of monitoring hard-to-reach locations

One challenge before Industry 4.0 was carrying out predictive monitoring in places that needed to be made accessible or far from the center. This is because data collection was done manually, and the logistics of professionals at each piece of factory equipment had to be considered.

Today, wireless sensors monitor equipment in dangerous environments and places that are difficult to access or far from urban centers since the data is sent directly to the monitoring company’s database and analyzed by professionals with expertise.

5. Much more frequent monitoring

The wireless sensor for predictive maintenance allows monitoring to be done remotely much more frequently than traditional predictive maintenance, which used to be done once or twice a month, depending on the park’s size and the company.

In the traditional method, asset maintenance in the field requires the periodic dispatch of technical teams, which involves high costs in terms of time, resources, logistical complexity, and a low collection rate.

6. Avoids losses from downtime costs

According to a study by Emaint, factories lose between 5% and 20% of their production capacity due to downtime. This happens when equipment is unavailable, forming bottlenecks in the production line.

Around 82% of companies have experienced unplanned downtime in the last three years, according to a survey by Aberdeen Research. The report says unplanned downtime can cost a company up to $260,000 per hour.

The good news is that using predictive maintenance and artificial intelligence resources in data analysis helps prevent these machine failures and avoid unplanned downtime. Research by McKinsey shows that predictive maintenance reduces machine downtime by 30-50% and increases the useful life of assets by 20-40%.

7. Faster responses to problems

When a predetermined limit for machine operation is reached, an alert is generated immediately, and analysts have instant access to machine condition data. They can then conduct precise analyses through asset management software, in real-time and from anywhere.”

Avoid unforeseen events! Have wireless sensors monitoring your equipment 24/7

Your industrial park can also benefit from Industry 4.0 technologies in predictive maintenance. SEMEQ has know-how and experience in this area and uses traditional and predictive maintenance techniques. We currently have one of the most technological and sensitive sensors on the market, capable of identifying even minimal vibrations in each piece of equipment.

SEMEQ wireless sensor

  • 10kHZ sensitivity – detects bearing and gear failures;
  • Up to 3 years of battery life and replaceable;
  • No need to discard the sensor when the battery runs out;
  • 3G/4G connection and independent operation;
  • Triggers and variable load.

Our company has over 300 employees and a portfolio of more than 500 monitored factories in 45 countries.

Contact us to have your industrial park fully monitored.

How can predictive monitoring be applied in the food industry?

Technology is playing an increasingly important role. Predictive monitoring is one of the innovations that has profoundly transformed the food industry. 

This approach uses sensors, real-time data, and advanced analytics to predict equipment failures, optimize maintenance, and improve operational efficiency.

This article will explore how to apply predictive monitoring in food industries, discussing the benefits, challenges, and best practices for implementing this technology effectively.

Main challenges in industrial food plants

Maintenance in industrial food plants faces several crucial challenges to guarantee the continuity of operations and the quality of products. Some of the main ones include:

Risk Management

Risk management is a crucial obstacle in maintaining industrial facilities in the food sector. By their nature, operations involve inherent risks, making it essential to implement rigorous safety measures to safeguard equipment integrity and workers’ protection.

One strategy for tackling this issue is establishing a solid safety program, including a thorough risk assessment, identifying potential hazards, drawing up a standard operating procedure (SOP), and periodic staff training. In addition, predictive monitoring in the food industry is essential to mitigate the risk of failures and accidents.

Asset management

Asset management represents a substantial challenge in the maintenance of industrial facilities. Preserving the functional state of equipment and machinery is fundamental to ensuring their proper performance over time. However, asset management is a complex task that requires thorough planning and efficient execution.

One strategy to overcome this challenge involves adopting a data-driven approach, which entails collecting data related to equipment and machines to monitor their performance and identify potential problems at an early stage.

Availability of resources

The availability of resources is a third major challenge in the maintenance of industrial facilities. Maintenance requires a wide range of resources, including workforce, equipment, tools, and materials. However, ensuring these resources are readily available when needed can be challenging.

An effective strategy for tackling this challenge involves developing a detailed maintenance plan and efficiently allocating resources.  Ensuring that the necessary resources are available before maintenance execution is essential

Online predictive monitoring is the key to increasing plant performance.

Predictive monitoring in the food industry is a maintenance technique that uses sensors and analysis to predict failures in industrial equipment before they occur. This helps to: 

  • Avoid unplanned downtime;
  • Reduce damage to equipment;
  • Optimize the useful life of machines; 
  • Reduce energy costs;
  • Ensure the health and safety of employees;
  • Minimize environmental impacts.

Based on the analysis, ultrasound, and thermography results, periodic monitoring aims to reduce problems and increase the useful life of equipment. 

This approach allows for creating a targeted action plan to restore optimal equipment performance and increase your plant’s performance.

Why carry out online monitoring in the food industry?

By understanding maintenance models, it is possible to see the gains that can be made in the food industry through management based on planning, emphasizing predictive and preventive actions. These benefits include

  • More excellent continuity on the production line: by adopting predictive monitoring in the food industry, the company can significantly reduce the number of unscheduled stoppages on its production line;
  • Planned interventions: maintenance interventions are conducted in a planned manner without affecting ongoing production;
  • Increased equipment useful life: predictive maintenance helps to extend the lifespan of equipment, reducing the need for frequent replacements and saving resources.

In addition to these benefits, it is important to highlight another significant advantage. When maintenance management is based on predictive actions, corrective procedures become more precise because they are carried out according to prior planning.

The maintenance team is adequately prepared with the appropriate use of tools and protective clothing. It can handle the critical elements of the equipment with care, avoiding any direct contact with production.

How online predictive monitoring is carried out in plants

Online predictive monitoring in industrial plants is an essential strategy for efficient equipment maintenance and ensuring continuity of operations. It is based on advanced techniques that make it possible to identify problems before they cause unplanned downtime.

Use of online sensors

One of the bases of online predictive monitoring is the sensors installed in the plant’s strategic equipment. These sensors are chosen in advance by the technical team and the maintenance manager, taking into account the critical points of each machine. The great advantage is that these sensors are wireless, which means they are installed on several machines without complex cabling.

These sensors collect a range of data, such as vibration, temperature, pressure, and oil consumption. This information is sent to a central database that gathers data on the monitored equipment’s performance.

Implementing platforms for data monitoring

With the data collected by the sensors, it is possible to create a monitoring platform that is accessed remotely. This platform can be viewed on various devices, such as computers, tablets, and smartphones, giving maintenance managers flexibility.

When any anomaly is detected, even the slightest vibration, the platform sends an alert to the maintenance manager. This allows the technical team to act proactively, planning corrective actions before a serious fault occurs.

How SEMEQ can help with predictive monitoring in the food industry

SEMEQ is a company specializing in advanced predictive monitoring solutions, with expertise in meeting the specific needs of the food industry. Our innovative approach and cutting-edge technologies are designed to optimize equipment maintenance and ensure maximum operational efficiency in food processing facilities.

SEMEQ sensors

Our state-of-the-art sensors are designed to meet the highest standards of quality and reliability. They are ideal for the food industry, where precision and early detection of anomalies are essential. Wireless sensors monitor real-time vibration, temperature, pressure, humidity, and other critical parameters.


The My SEMEQ platform answers the need for real-time data monitoring and management. 

Maintenance managers in the food industry, with access to this platform, monitor the performance of their equipment remotely, receive instant alerts about any problems detected by the sensors, and access valuable information for informed decision-making.

If you are looking for reliable and customized predictive monitoring solutions for the food industry, SEMEQ is ready to help. 

Contact us

Contact us today to discuss your specific needs and find out how our sensors and platform can improve the efficiency and reliability of your maintenance operations.

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Online asset monitoring: the reason why it is essential for a high-performance plant

Online asset monitoring

Online asset monitoring in an industrial plant is an important solution to ensure reliability and operational efficiency.

Technology is used to collect real-time data from equipment and systems, enabling failure detection and preventive maintenance planning. It is possible to reduce downtime, decrease costs with corrective maintenance, extend the useful life of equipment, and increase worker safety.

Another benefit is that asset monitoring allows more precise management of resources, such as energy and materials, resulting in greater efficiency and reduced operating costs.

This article explains online asset monitoring and its advantages for the production plant. Besides that, you will learn about the importance of the Internet of Things (IoT) and cloud storage in this process.

What is online monitoring?

Online asset monitoring tracks through sensors that collect information such as energy consumption, temperature, and vibration. This data is sent to a platform before being analyzed and turned into graphs about machine performance.

Benefits of online asset monitoring

Among the main advantages of implementing online monitoring in your factory are the following: 

  • Reduced maintenance costs
  • Reduction of unexpected failures
  • Increased control
  • Improved useful life
  • Increased reliability
  • Automation of maintenance processes

How do IoT and cloud storage support online monitoring?

The Internet of Things (IoT) and cloud storage offer several benefits to online asset monitoring, making the process more efficient, reducing expenses, and automating tasks.

To begin with, IoT contributes with smart sensors so that data from equipment is collected for the benefit of its conservation. This happens in real-time so teams can respond accurately to potential signs of failure.

Your business can store data without a physical space with cloud technology. Network connectivity allows information to be stored in the cloud. As a result, they are stored in protected facilities and away from the industrial plant.

To learn more about Predictive Monitoring Technology, click here:

Increase your business profitability with SEMEQ’s Digital Predictive Monitoring

Monitor your industrial plant 24/7 with Semeq

With one of the most efficient sensors on the market, Semeq is a reference in online asset monitoring. The company was founded in 1994 and is present in 40 countries worldwide. Altogether, we are 300 staff members working to maximize profitability and reduce operating costs in industrial plants.

How do we monitor your assets?

The online monitoring process starts with installing sensors that can identify asset behavior. Data is then collected and stored with the help of cloud connectivity.

The next step is data processing, with the support of artificial intelligence, which provides the best insights to maintenance teams. The processed data is further analyzed by Semeq’s team of experts, who are highly trained and qualified to ensure the quality of the diagnoses.

What tools do we use to monitor your assets?

Semeq offers a complete range of asset monitoring sensors to inspect your plant machinery in full time automatically.

Wireless vibration sensors

Semeq’s wireless vibration sensors monitor critical equipment and allow monitoring of points in dangerous and inaccessible locations. With this, your factory ensures the analysis of oscillations present during the operation of the machines, checking for potential failures.

Wireless temperature sensors

In addition, Semeq has temperature sensors. Through online monitoring, teams can take repair measures without the need to affect productivity due to machine downtime.

Oil analysis

Another important sensor is the one responsible for oil analysis. In this way, it is possible to take care of the preservation of the equipment and the conservation in ideal conditions for use. In addition, this analysis reduces spending on unnecessary oil changes.

Acoustic emission analysis

Semeq also analyzes the acoustic emission of the machines. The system is able to detect the degradation process through sound waves emitted by the assets.

Motor circuit analysis

Motor circuit analysis identifies problems caused by errors in the installation of power circuits. With our sensors, you can follow up on this type of failure, ensuring the fastest correction.

My Semeq

My Semeq is a fast and modern system for viewing your industrial plant’s results. The system has management, analysis, and reliability tools.

In this way, your company can access integrated reports to facilitate diagnoses and optimize results management. Users can still customize and access the dashboard in more than ten languages.

The platform is also available on different devices. You can access data from your computer or smartphone to simplify information management.

What results can we achieve?

With our solutions, your business reduces machine breakdowns by up to 90%. Otherwise, the increase in equipment life reaches 60%. The reduction in planning time can reach 70%, and the increase in time between failures can approach 60%.

Who trusts Semeq?

Semeq monitors 500 factories around the world. Among the companies that trust our solutions are:

  • Gerdau
  • JBS
  • Heineken
  • Bayer
  • Unilever
  • Ultragaz
  • Coke
  • AB InBev

Talk to our specialists and have guaranteed protection for your plant.

Did you like to learn what online monitoring is and what are the benefits of using this technology?

So, take the opportunity to ensure the protection of your industrial plant today! Visit our contact page, fill in the details, and send a message to speak with our specialists.

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Thermography in predictive maintenance: how it can impact your financial results?

The thermography technique in predictive maintenance uses technology to analyze the temperature of equipment, making it automatic and without interference in production.

In this article, you will understand how temperature measurement sensors identify equipment problems and check the benefits of using thermography to identify potential failures. Enjoy your reading! 

How is the detection of anomalies done with the measurement of equipment temperature?

Thermography is a technology that identifies possible problems in equipment using infrared sensors and cameras. The resource allows the temperature of the machinery to be analyzed and makes it possible to correct it before it becomes defective.

The anomalies are detected the moment the instrument recognizes minimal temperature changes.

In this process, contact or non-contact meters are used. In the first case, the resources must contact the system to identify the changes. On the other hand, non-contact meters evaluate using infrared radiation, which finds differences and sends alerts.

We can do this analysis on moving objects or even at high temperatures. Thus, non-contact thermographic measurement is essential for predictive maintenance since it can be done without interrupting production. 

Applications of thermography in predictive monitoring

The use of thermography in predictive maintenance can have the following applications:

  • Rotating equipment: thermography ensures that equipment does not heat up while running, decreasing failures and contributing to thermal balance.
  • Electrical installations: temperature measurement detects failures, such as corroded and oxidized connections.
  • Electric machines: generators, motors, and transformers must be carefully evaluated to prevent problems and keep up with aging.

Benefits of using thermography in predictive maintenance

Thermographic analysis in predictive maintenance is essential to ensure good industrial equipment maintenance. In order to be successful in anticipating failures, companies need this kind of technology.

Check out the main advantages of having this resource in your manufacturing plant.

Reduced Maintenance Expenses

Component failures during operation can lead to unexpected costs for organizations. In this sense, thermography checks the progress of components in the process to see if there is a risk of overheating.

In addition, by reducing the expenses for equipment maintenance, thermographic analysis also improves the financial predictability of your business.

Increase in machines’ useful life-cycle. 

The use of temperature sensors can increase the useful life of industrial plant equipment. With the reduction in the record of failures and accidents, the machinery must perform well for longer.

In this way, they also reduce the costs of acquiring new parts. Your company can have better stability and direct the financial budget towards investments that can guarantee the best positioning of your business in the market.

Improving productivity

Thermography in predictive maintenance allows the efficient progress of the production flow without the breakage of components. As a result, the technology improves the productivity of the manufacturing plant.

Count on Semeq to prevent failures.

Semeq has a vibration and thermography sensor that identifies abnormal movements and unusual temperatures. In addition, we have the expertise of being one of the leading companies in predictive monitoring, being a reference in the market. 

See below other points that make Semeq the main partner of companies.

Reference in the market for almost 30 years

Since 1994, Semeq has been providing technology and innovating in the market. The company was founded in the city of Limeira, in São Paulo, and today it operates in 40 countries. In all, around 500 industrial plants are monitored monthly.

A team committed to results

Our team has 300 employees to provide accurate results for your business. They are engineers, technicians, analysts, and data scientists who strive to increase the efficiency of your industrial plant and transform monitoring into financial results.

Complete line for predictive maintenance

Semeq has a wide range of systems for predictive maintenance monitoring, skilled labor, and technical support. Thus, you invest in the best performance of your production line.

Smart Sensors

Semeq inspects your machines automatically and uninterruptedly using its Intelligent Sensors. The data is collected with wireless technology, sending details about the equipment’s performance to a database.

The information collected by the sensors indicates vibration, temperature, pressure, or abnormal consumption of the equipment. Thus, you get the data through a platform accessible on different devices and can issue an action plan to get the machinery working at maximum performance again.

Be ahead of the unforeseen. Talk to us now!

Wireless sensors for online monitoring: why they are the best option on the market? 

Wireless online monitoring sensors have changed how machine data is collected, transported, and analyzed.

They have been used by companies that want to have more effective control of the situation and performance of their machines since it is possible to obtain data collected with high frequency and precision by being done remotely.

This type of sensor is especially interesting for large industrial parks, which have continuous or intermittent production, or those located in difficult access points or far from large centers, thus avoiding installing large and wired networks.

In this article, we will show the benefits of using wireless sensors for online monitoring and why it has been the best choice for those who want to maintain high performance in industrial plants.

Technology in predictive maintenance: software’s help has changed how we do the monitoring. 

Predictive maintenance began in the 1940s in the US air force. In the 1970s, the use of offline data collectors increased, but today we know that they demand much manpower.

Traditional predictive maintenance consisted of making collections with data collectors, also called datalogs, through a single sensor attached to the end of the equipment from a cable. It was a portable instrument that required the presence of a person to collect data at the factory, usually on a monthly basis.

With Industry 4.0, as of mid-2015, the wireless sensor system for online monitoring began to emerge; at that time, the installation involved investments in infrastructure, with large cable networks to transmit the information.

The quality of remote monitoring of the machines has improved significantly since the cadence of collection, which was monthly, can now be 700 times greater.

In this way, online inspection became much more accessible. It began to be carried out in bulk, always with the same objective: to guarantee the proper functioning and availability of the machines.

Nowadays, remote monitoring with wireless sensors has virtually no limitation in its expansion, changing the amount of monitored equipment from hundreds to thousands. One of Semeq’s customers will install around 50,000 sensors in the next few years in its manufacturing plants.

Benefits of using wireless sensors for online monitoring

Wireless networks dramatically reduce the costs of installing, maintaining, and performing asset monitoring systems.

Check out some benefits of using wireless sensors for online monitoring.

Association of vibration sensors with analysis of electrical circuits.

Vibration analysis and electric motor circuit analysis sensors cover 100% of faults; 67% of failures are covered by vibration analysis, and 33% by circuit analysis of electric motors.

Prescriptive insights 

The most modern approaches to preventive maintenance use machine learning and AI to discover valuable insights from data. With these capabilities, sensor solutions identify potential failures and predict how long a machine or process may have before it fails.

It is important to note that artificial intelligence and machine learning systems need much historical data to learn.

Thus, unlike other predictive monitoring companies, Semeq has the largest database on the market, around 70TB, allowing the application of AI and ML to be more accurate and application development to be faster. 

Companies that do not have a robust database will have to wait for machines to break down numerous times before they can “train” their AI systems, exposing their equipment to failure.

Spectral Analysis

When capturing frequencies, they are transmitted in grouped (mixed) form. In Semeq’s algorithms, they are classified mathematically, which allows interpretation of the various failure modes leading to accurate determination of potential failures.

Our algorithms also rely on Artificial Intelligence and Machine Learning based on our extensive databases, as mentioned above.

Prescriptive analytics report

MySemeq, our report delivery platform, allows viewing the diagnoses of all predictive techniques and performing results management in a single place.

Integration with the ERP allows for automatic service orders with fast and consistent feedback. It also improves the follow-up of work orders and ensures the execution of reports.

Wireless sensors for online monitoring: online vibration and temperature analysis.

Due to technologies such as Bluetooth, many more wireless sensors can now be connected to machines. These wireless sensors for predictive monitoring service capture critical data online that is transmitted to a central cloud server via a wireless gateway.

Our online vibration sensors detect numerous potential failure modes in equipment. By associating vibration and temperature analysis, they broaden the detection possibilities, significantly increasing system reliability.

Learn about some advantages of our wireless sensors for online monitoring.

Early-stage failure detection

When a limit determined by our algorithms is reached, an alert is generated, and analysts have access to the machines’ condition data. In addition, SEMEQ’s algorithms allow forecasts leading to the estimation of the time available for the execution of the maintenance.

Quick Setup

Wireless sensors for online monitoring can be installed very quickly, without wires, compared to traditional wired monitoring. After all, the energy for its operation comes from replaceable batteries.

Some companies offer sensors with non-replaceable batteries, leading to the need to completely replace the sensors, which ends up being financially unsustainable. For example, imagine a plant with thousands of sensors discarded every time the batteries run out; ultimately, the budget becomes impractical for many companies.

With a configurable and scalable system, you can add hundreds of wireless sensors and configure each individually.

Flexibility in applications

The most diverse equipment benefits from online monitoring. The predictive maintenance service can be applied to engines, power systems, boilers, steam system components, gearboxes, bearings, etc.

Find out how we carry out online monitoring of machines in industrial plants.

SEMEQ cares about machine health, while other companies care about disease. SEMEQ’s significant role is to bring this predictive and preventive culture, allowing potential machine breakdowns to be identified early enough for interventions to be more effective.

Installation of sensors for data collection

With the online system, sending a person to collect data is unnecessary, as it is done automatically. With these remote monitoring features, around 720 data collections are made monthly, a much more significant number than the offline collection, usually done only once or twice a month. In this way, the chances of a failure occurring are drastically reduced.

Results Management

Semeq’s wireless sensors for predictive service and our team collect data, and our labs analyze these algorithms. Then, our engineers manage the results, presenting the best machine maintenance solutions.


Our predictive service and remote monitoring of plants identify gaps in industrial parks, suggesting actions and corrections that should be prioritized.

Choosing the most suitable technique depends on the type of machine and the needs of each company. Our team of professionals with expertise in predictive maintenance performs this analysis.

We are a reference in online predictive maintenance monitoring.

SEMEQ has 300 employees and over 500 monitored factories, with a presence in 40 countries. To meet customer needs, our predictive monitoring company has teams to advise on installing and improving maintenance models distributed worldwide. In contrast, the analysis team is concentrated in our control rooms.

Talk to our consultants and avoid surprises at your industrial plant!

Industry predictive service: increase the useful life of your machinery with SEMEQ 

Predictive, preventive, and corrective maintenance services are crucial for properly functioning industrial parks with uninterrupted production. That is why monitoring has advanced over decades regarding production and data accuracy.

In SEMEQ, we have developed technologies with our professional team to offer better and better predictive monitoring services. Nowadays, we have control software, smart data collection sensors, oil analysis laboratories, and a team of experts to create advanced algorithms with artificial intelligence.

This article presents the benefits of predictive services for industries and why SEMEQ is the best choice for those who want industrial plants free of contingencies.

What are the impacts caused by equipment wear in industrial plants?

For a company to be efficient in its production process, it needs to have maximum control over the factors that affect its production. After all, machine failures can compromise their useful life and lead to downtime in the production process, generating huge losses for companies.

When equipment presents wear in parts or mechanical failures, this causes a series of losses, such as

  • Expenses with replacement parts;
  • Expenses with repair labor;
  • Unexpected production stops;
  • Machine downtime;
  • Decrease the productive potential of the industrial plant;
  • Expenses with more energy consumption;
  • Compromised final product quality;
  • Lack of machine availability.

How does the predictive monitoring service work around these challenges?

According to consultancy McKinsey & Company, predictive maintenance service increases the availability of a production line by up to 15% and can also reduce maintenance costs by up to 25%.

An efficient predictive service for industries helps to avoid unnecessary downtime, thus increasing operational efficiency and productivity and reducing costs. In addition, it helps to prevent further damage, extend component life, and improve machine reliability.

To make this possible, sensors installed on the machines or data collectors are used, which can work offline and online. These sensors and collectors can measure the equipment’s vibration, thermography, and ultrasound conditions, ensuring that any abnormal movement is identified before failure occurs.

In addition to smart sensors, predictive monitoring in Industry 4.0 also uses software capable of storing large amounts of data, providing valuable information for analyzing machine conditions.

Perform predictive monitoring of your equipment with SEMEQ

SEMEQ is a prestigious predictive monitoring company in the market. We monitor equipment online or offline, ensuring the availability of machines in your industrial plant.

Based on our experience of almost 30 years, we know the exact requirements for remote monitoring of your machines and ensuring the continuity of your production line.

In addition, we also practice traditional monitoring with equipment oil analysis, and we count on an internal team of experts to build highly competitive sensors integrated with the most advanced machines in the market.

Learn about the differentials which make SEMEQ a leader in the market.

Detection of all failure modes

SEMEQ’s intelligent online vibration sensor detects more than 50 potential modes of electrical and mechanical faults. Vibration analysis and temperature analysis can cover 100% of potential failure modes.

Integrated monitoring (online and offline)

SEMEQ performs the integrated monitoring of equipment, combining online monitoring through smart sensors and offline monitoring with traditional data collection for laboratory analysis.

So, we can monitor your equipment 100% for the predictability of potential failures, keeping the machine at its maximum efficiency.

Experts with experience in detecting failures. 

With more than 29 years of experience, SEMEQ has the expertise of professionals specialized in detecting failures and generating insights to increase the productivity of your equipment.

Presence in 40 countries

SEMEQ has over 300 employees and more than 500 monitored factories in its portfolio, with a presence in 40 countries.

Experience in more than 10 segments

Industries from the most diverse sectors significantly gain from online and offline monitoring. The predictive service can be applied to engines, electrical power systems, boilers, steam system components, transformers, gearboxes, and refrigeration systems, among other equipment.

Find out how we carry out predictive monitoring in your industrial park


In the lab, Artificial Intelligence technology sifts and points out the probability of some parts failing in the machines. Remote and traditional monitoring techniques, such as vibration studies and lubricating oil analysis, are used to evaluate the condition of the equipment.

The choice of the most appropriate technique depends on the type of machine and the needs of each industry. Based on this diagnosis, it is possible to map which equipment will most likely fail in the customer’s plant.

Fusion of techniques

Another differential of SEMEQ is the possibility of working with several combined techniques. This is because each use of multiple techniques allows better detection of failures.

Therefore, we use a combination of predictive approach techniques to increase the accuracy of our analyses.

For example, to identify the problem in a gearbox, we can do a vibration analysis and combine it with an oil analysis. This mixture of techniques further enhances the ability to detect problems.

Talk to our consultants and avoid failures 

SEMEQ helps your industry to define which equipment should be monitored, which predictive techniques should be applied, and what monitoring cadence should be used.

Talk to our consultants