IoT Knowledge
Existing production facilities can be modernized step by step—using retrofit and IIoT technology. Together with our customers, we identify opportunities, implement new sensor technology and connected systems, and create measurable added value. We have already implemented successful projects at the Chempark sites, such as Smart Steam, Wells, and Water Metering.
Step 1: Assess the current situation and objectives
Before introducing new technologies, we work with you to analyze your existing infrastructure and define your goals. In doing so, we examine both the technical framework and your business processes to identify opportunities for optimization.
Common challenges in practice:
- Limited data availability or inaccurate data due to manual entry
- Unplanned downtime and inefficient processes due to a lack of transparency
- Reactive maintenance that causes production downtime
- Strict regulatory requirements and compliance obligations
- Rigid production processes that make it difficult to adapt quickly to market conditions
- High energy costs due to inefficient supply
With a clear analysis, we lay the groundwork for selecting the right IIoT solutions.
Step 2: Create a test scenario & collect data
Based on the analysis, we work with you to identify critical systems, components, or processes that would benefit from an IIoT solution. This may involve, for example, an upgrade of communication technology—such as replacing outdated DECT systems with Private 5G to ensure stable, secure, and high-performance connections.
We start with a test scenario that generates initial data, which is then analyzed and visualized. This allows us to quickly identify scalable opportunities for cost savings and efficiency improvements. At the Chempark sites, three scenarios have already proven particularly effective:
- Smart Steam: Efficient Monitoring and Control of Steam Systems
- Wells: Optimized Water Supply and Management
- Water Metering: Precise Monitoring of Water Consumption
Step 3: Measuring Success & Continuous Adjustment
Once the test scenario has been initiated, data collection and analysis begin. Modern analysis tools convert large amounts of data into actionable insights—ranging from machine status and position tracking to environmental and energy monitoring.
Typical use cases:
- Monitoring of machine parameters: temperature, pressure, vibrations, fill levels
- Live tracking of vehicles or objects
- Environmental monitoring: air and water quality, humidity, noise
- Energy Consumption Measurement: Optimization of Heating, Cooling, and Lighting Systems
Based on the data collected, it is possible to implement predictive maintenance, reduce downtime, and improve energy efficiency. Through ongoing analysis, the implemented solutions can be continuously optimized to maximize the benefits of the technology. Successful IIoT retrofit projects deliver measurable benefits: higher production output, increased energy efficiency, reduced downtime, and improved employee satisfaction through optimized working conditions.
Conclusion & Recommendations
Retrofitting existing industrial facilities with IIoT (Industrial Internet of Things) technology is more than just a technical update—it is a crucial step toward future-proofing. By digitizing production processes, companies gain valuable insights into their operations, make better data-driven decisions, and increase their efficiency. The result: tangible cost savings and a significant contribution to greater sustainability.