Production is going on.
APAC industrial equipment maker cuts downtime 45% with IIoT
BCT connected AFE’s installed equipment without replacement, giving teams live fleet visibility and early warning.
Client
Challenge
An industrial equipment manufacturer in APAC supplied compressed air dryers and nitrogen generation systems to process industries including pharmaceuticals, food and beverage, electronics and chemical processing. In these environments, compressed air is a direct production input. A dew point excursion or contamination event can halt a production line, spoil a batch or create a regulatory exposure.
The manufacturer’s problem began after installation. Once a machine reached a customer site, its performance was largely invisible to the manufacturer. Dew point, pressure, temperature and gas purity could be read at the machine, but not continuously from a central view. Failures were therefore discovered after a trip or contamination event, when the customer had already felt the operational impact.
The installed base also spoke several data languages. Different machine models and controller generations reported differently, making fleet-wide monitoring difficult to scale. Compliance evidence relied on physical logs that were slow to produce and difficult to monitor continuously.
The manufacturer needed to move from equipment that was reliable at the point of sale to equipment whose performance could be continuously demonstrated in operation.
The manufacturer’s problem began after installation. Once a machine reached a customer site, its performance was largely invisible to the manufacturer. Dew point, pressure, temperature and gas purity could be read at the machine, but not continuously from a central view. Failures were therefore discovered after a trip or contamination event, when the customer had already felt the operational impact.
The installed base also spoke several data languages. Different machine models and controller generations reported differently, making fleet-wide monitoring difficult to scale. Compliance evidence relied on physical logs that were slow to produce and difficult to monitor continuously.
The manufacturer needed to move from equipment that was reliable at the point of sale to equipment whose performance could be continuously demonstrated in operation.
Solution
BCT designed and delivered an industrial IoT platform using two BCT-owned products: the Common Data Platform and Retina IIoT. The platform ran on cloud infrastructure in APAC and, critically, connected the manufacturer’s existing machines. No unit was replaced and no customer production was interrupted during rollout.
Each connected dryer streams 66 operational tags and each nitrogen generator streams 32 tags directly from existing controllers. Across the connected fleet, that produced 2,504 live measurement points captured continuously.
The Common Data Platform provides the common language. Its adapters translate different machine models and controller generations into a standardized data structure. Multiple adapter versions can operate side by side, so newer equipment can be added without disrupting the rest of the fleet.
Telemetry moves into a managed cloud database designed for sustained analytical use. Per-asset data structures and pre-computed aggregates keep queries responsive as history accumulates. Retina IIoT then provides live gauges, historical trends, fleet health scores, machine-level drill-down and alarm intelligence. Instead of recording only that an alarm occurred, the platform records how long each abnormal condition persisted.
The platform also generates scheduled operational and air-purity compliance reports automatically. A daily health report monitors infrastructure utilization, service availability, pipeline throughput, per-machine processing and open alarms, allowing degradation in the monitoring environment itself to be detected early.
Each connected dryer streams 66 operational tags and each nitrogen generator streams 32 tags directly from existing controllers. Across the connected fleet, that produced 2,504 live measurement points captured continuously.
The Common Data Platform provides the common language. Its adapters translate different machine models and controller generations into a standardized data structure. Multiple adapter versions can operate side by side, so newer equipment can be added without disrupting the rest of the fleet.
Telemetry moves into a managed cloud database designed for sustained analytical use. Per-asset data structures and pre-computed aggregates keep queries responsive as history accumulates. Retina IIoT then provides live gauges, historical trends, fleet health scores, machine-level drill-down and alarm intelligence. Instead of recording only that an alarm occurred, the platform records how long each abnormal condition persisted.
The platform also generates scheduled operational and air-purity compliance reports automatically. A daily health report monitors infrastructure utilization, service availability, pipeline throughput, per-machine processing and open alarms, allowing degradation in the monitoring environment itself to be detected early.
Impact
The platform has operated continuously in production for 14 months since June 2025. Forty machines—36 industrial dryers and four nitrogen generators—are connected without equipment replacement. The fleet streams and analyzes 2,504 live tags and processes more than 17 million records every day, with approximately 5 GB of raw telemetry captured daily.
Analytical response remains sub-second across live and multi-month historical data, while 100% of raw telemetry is retained for historical reconstruction.
The manufacturer reports a 45% reduction in unplanned equipment downtime through early warning on dew point and pressure anomalies. Mean time to repair fell 30% as technicians used alarm-duration history and trend data rather than relying on on-site investigation. Energy efficiency improved 15–20% through analysis of compressed-air flow against pressure drop.
Onboarding time fell 85%, from approximately three days to around 30 minutes per machine. Air-purity and dew-point compliance reporting became 100% automated.
The strategic change is commercial as much as technical. The installed base is no longer a collection of machines that disappears after shipment. It has become a connected estate whose performance can be measured, diagnosed and demonstrated in operation.
Analytical response remains sub-second across live and multi-month historical data, while 100% of raw telemetry is retained for historical reconstruction.
The manufacturer reports a 45% reduction in unplanned equipment downtime through early warning on dew point and pressure anomalies. Mean time to repair fell 30% as technicians used alarm-duration history and trend data rather than relying on on-site investigation. Energy efficiency improved 15–20% through analysis of compressed-air flow against pressure drop.
Onboarding time fell 85%, from approximately three days to around 30 minutes per machine. Air-purity and dew-point compliance reporting became 100% automated.
The strategic change is commercial as much as technical. The installed base is no longer a collection of machines that disappears after shipment. It has become a connected estate whose performance can be measured, diagnosed and demonstrated in operation.
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