Intelligent Monitoring for Industrial Reliability

IAC Smart Plant™ Suite is a remote monitoring and predictive maintenance platform engineered to improve equipment reliability, environmental compliance, and operational visibility across industrial facilities. The system connects wireless, non-intrusive sensors to critical assets, including dust collectors, rotary equipment, motors, fans, conveyors, and bulk storage. Smart Plant™ delivers real-time insight into performance trends so operators can detect early signs of degradation, prevent downtime, and extend equipment life.

Smart Plant™ Suite also functions as a plant-wide AIoT platform, supporting Smart Industry applications such as airflow visibility, dust management, pressure monitoring, and environmental sensing. Using long-range LoRaWAN wireless architecture, Smart Plant™ enables secure communication across large facilities without complex wiring. Data from vibration, ultrasound, temperature, pressure, differential pressure, particulate behavior, and level sensing is unified into a single dashboard.

The platform powers the RotaryIQ, DustIQ, SiloIQ, Pulse Valve, and PressureIQ modules. Each module is tailored to the operational needs of mechanical, filtration, or storage systems, giving maintenance and operations teams a more complete view of system behavior and compliance performance.

Designed for harsh industrial environments, Smart Plant™ integrates with MCCs, PLCs, SCADA, and CMMS. It can support a single dust collector or scale to multi-site enterprise deployments. With continuous monitoring and actionable analytics, Smart Plant™ creates a reliable path to plant-wide performance improvement.

Smart Plant™ Monitoring Modules

The Smart Plant™ Suite addresses the systems that most influence reliability, throughput, environmental compliance, and plant-wide performance. Each module focuses on a critical asset group and provides continuous visibility into its operating health, supported by long-range LoRaWAN wireless connectivity for flexible deployment.

DustIQ – Real-Time Dust Collector and Emissions Monitoring

DustIQ provides real-time visibility into dust collection system health. It monitors differential pressure, pulse cleaning behavior, fan performance, and particulate levels to detect off-normal cleaning cycles, broken bags, or airflow imbalances. DustIQ supports longer filter life, more consistent collection efficiency, and improved environmental compliance. Plants rely on DustIQ to avoid visible emissions events and maintain stable process airflow.

PressureIQ – Differential Pressure and Compressed Air Monitoring

PressureIQ provides real-time monitoring of differential pressure, header pressure, and airflow-related behavior across dust collection systems. It detects DP drift, air supply inconsistencies, pulse strength issues, and airflow imbalance before they impact compliance or filter life. PressureIQ supports both DustIQ diagnostics and facility-wide dust management.

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Smart Plant™ Pulse Valves – Enhanced Cleaning Performance and System Insight

Smart Plant™ Pulse Valves improve cleaning effectiveness and reliability within pulse-jet collectors. They deliver consistent air delivery and timing for stable differential pressure and longer bag life. When paired with DustIQ and PressureIQ, Smart Plant™ Pulse Valves provide advanced visibility into diaphragm performance, air header behavior, and cleaning efficiency. This supports proactive maintenance and consistent dust collector performance.

SiloIQ – Accurate Silo Level and Inventory Monitoring

SiloIQ uses high-precision, non-contact level sensing to measure material volume inside silos, bins, and storage vessels, even in dusty or high-temperature environments. It improves inventory accuracy, reduces manual inspection risks, and supports better production planning and delivery coordination across multiple locations.

Smart Plant™ Capabilities and Technical Advantages

Smart Plant™ provides continuous visibility into equipment behavior, airflow conditions, material levels, and dust management performance. The system combines multi-sensor data, edge intelligence, and cloud analytics to give operators a clearer understanding of how equipment is performing and where corrective action is needed.

Real-Time Condition Monitoring Across Critical Systems

Smart Plant™ collects vibration, ultrasound, temperature, pressure, differential pressure, airflow, particulate levels, and level measurements across rotating equipment, dust collectors, and storage systems. This creates a unified view of reliability, compliance, and material flow.

Predictive Maintenance Insights and Early Warning Detection

Edge-based analysis identifies trends that signal developing mechanical, filtration, or airflow issues. Smart Plant™ alerts operators to early bearing wear, misalignment, lubrication needs, rising differential pressure, failing pulse valves, compressed air inconsistencies, broken bags, and declining airflow efficiency. This supports scheduled maintenance instead of reactive repairs.

Integrated Pulse Cleaning and Pressure Diagnostics

DustIQ, PressureIQ, and Smart Plant™ Pulse Valves work together to provide cleaning cycle visibility, diaphragm behavior analysis, and differential pressure tracking. This combination helps operators correct cleaning inefficiencies, reduce energy waste, and extend filter life while maintaining consistent dust collector performance.

Environmental and Compliance Visibility

Smart Plant™ tracks particulate levels, airflow patterns, DP stability, temperature, and emissions-related behavior to help plants identify off-spec conditions early. This reduces the likelihood of visible emissions events and strengthens compliance with environmental requirement

LoRaWAN Wireless Deployment for Scalable Coverage

Smart Plant™ uses long-range LoRaWAN connectivity for secure, low-power communications across large industrial sites. This eliminates the cost and disruption of wired installations, simplifies expansion, and supports sensors in elevated, remote, or hard-to-access areas.

Scalable Deployment Across Single Units or Enterprise Operations

Smart Plant™ can be deployed on a single collector or expanded to multiple lines or facilities. Centralized dashboards provide standardized reporting and visibility across the enterprise, enabling consistent maintenance practices and performance tracking.

Enterprise Dashboards and Multi-Site Analytics

Smart Plant™ consolidates machine-level and plant-level insights into a unified cloud dashboard. Operators and managers can compare sites, standardize maintenance programs, configure alarms, automate reporting, and support broader reliability and compliance initiatives.

Request a Demo or Technical Consultation

Smart Plant™ gives maintenance teams, environmental managers, and plant operators the visibility they need to keep production running reliably and efficiently. Whether you want to strengthen dust collection performance, improve mechanical reliability, or deploy plant-wide monitoring through wireless AIoT technology, our team can help you evaluate the right path forward.

Connect with IAC’s Automation and Controls Team to discuss integrating Smart Plant Remote Monitoring into your new or existing systems and see how remote insights can transform your operations.

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