Industrial machinery

Monitoring for industrial machinery and manufacturing equipment

What do you need monitored? DCO’s industrial machinery and manufacturing monitoring solutions can update your existing equipment and bring it into the 21st century. Equipment sensors are easily retrofitted or installed to machines and equipment. Furthermore, energy harvesting capabilities allow for monitoring in hard to access locations with little infrastructure.

DCO's machine monitoring can unlock hidden data within air handler units and provide better information
DCO sensors specialise in machine monitoring such as boilers, steam traps and pipework
DCO 's machine monitoring can provide insight for heat exchangers and other legacy equipment
DCO sensors special in machine monitoring such as industrial fans

Motors and drives

Turning electrical power into mechanical action, motors benefit from a combination of electrical and physical monitoring techniques. Motor current signature analysis (MCSA), temperature and vibration monitoring can be combined to deliver real-time performance metrics and to form the longer term data set required for predictive and preventative maintenance.

Expensive, state-of-the-art motors often have these capabilities built-in, but most installations are reliant on simpler, lower cost and often older motors. The ease of retrofit of DCO sensing solutions enables these pre-existing motors to acquire the same monitoring capabilities and performance metrics.

Drive motors are frequently combined with other mechanical components such as gearboxes, pulleys, belts, and drive shafts. These components can also benefit from use of sensing to monitor their performance. READ MORE


Actuators (electric types) generate rotational and linear mechanical action from electric motors. Therefore, they benefit from many of the same monitoring techniques as are used in rotational drive motors. However, there can be subtle differences in the requirements and particular attention is paid to short-term and transient current analysis in combination with torque measurement.

Performance metrics monitored for actuators include peak currents, torque and rates of change. Depending on the physical configuration vibration sensing can also help to assist in fault detection and diagnosis.

Heat exchangers

For heat exchangers, monitoring the temperature, pressure and flow all serve as important indicators that can verify the health and functionality of your equipment. Knowing the fluid inlet and outlet temperature as well as the fluid mass flow rate can create an understanding of the heat transfer coefficient.

Heat (and energy) recovery systems

Heat, and energy recovery, units are typically specialised heat exchanger systems providing pre-heating, and/or full heating, of process fluids through the use the energy in waste and exhaust gases. The majority of the physical parameters monitored are common to other drive, actuator, ducts and pipework components. But multiple parameters monitored in conjunction allow for further specific insights into efficiency, utilisation, and energy consumption of the heat recovery system.

Heat recovery units are often part of a larger process and have a serious knock-on effect if they are not properly functioning. The economic costs of a heat recovery system that is not running properly can be significant. A typical multi-boiler recovery system can be saving upwards of $800 per day in fuel costs. Any downtime on such a system directly translates into increased fuel costs and, with most fuel sources, increased emissions.


Connecting various plant systems, sites and infrastructure, pipe networks can consist of multiple kilometres of over and underground pipework. Monitoring and maintaining that infrastructure is vital to the efficient and safe operation for many industries and processes.

In most process and plant installations pipework needs to be monitored for current performance factors (process and fluid temperatures, pressures, etc.). Such installations also benefit from more detailed physical monitoring of safety and process critical pipework sections. Monitoring of vibration, stress and strain enables better safety monitoring and optimisation of maintenance.

DCO Systems' expertise in, and solutions for, steam and condensate systems provides high value when used in steam supply and condensate return pipework systems and configurations. READ MORE

Air handling equipment

Monitoring of pressure in air systems can indicate performance loss in air handlers. Measuring temperature gives insight to the heating and cooling of coils, indicators for the efficiency of the overall operation.

Something else?

Didn't find what you are looking for? DCO Systems can customise monitoring solutions for a wide range of machinery and processes. We are constantly evolving our sensors to fit unique needs and processes. Get in touch to find out how we can help you.

DCO's machie monitoring can help modernise equipment and unlock the hidden inner workings of various equipment

Article: 'Modernise your machines - the nuts & bolts of what's really going on' explores how existing plant and equipment have a compelling story to tell, but may be prevented from speaking clearly. DCO’s technology can give them a voice! It’s time to modernise your machines and unlock the hidden data within heat exchangers, actuators, motors, air handlers, heat recovery units, steam traps, pipework and more ... READ MORE

DCO Systems can remotely monitor inaccessible steam infrastructure

Case study: 'Monitoring inaccessible steam infrastructures' details a major urban UK hospital site with an extensive steam network that is heavily used and sometimes inaccessible with steam passing through kilometres of underground pipework. Monitoring and maintaining that infrastructure is vital to the efficient and safe operation of a hospital on which patients rely, but access for manual measurement is hazardous and time-consuming. READ MORE

DCO Logo Simple

3 Global Business Park
14 Wilkinson Road
Cirencester GL7 1YZ
United Kingdom

+44 (0)1285 359059

Scroll to Top