Project Summary
The ControlPro Connect project was about making it simple to manage big factory air filters for a company called Plymovent. Before our work, managing these systems was difficult and caused big problems. We built a simple web tool that acts like the brain for all the filters and fans. This tool lets managers check and control everything easily from any computer. The system automatically finds problems, saves energy, and stops costly factory shutdowns.
About the Client
Plymovent is a major manufacturer of air-cleaning and filtering systems for factories. Their products are vital for keeping workers safe and stopping machines from getting dirty from things like dust and smoke. Plymovent is dedicated to lowering emissions, minimising waste, and utilising resources wisely. This causes our corporation to consider a technique to automate the extraction system using IoT solution.
The Challenge
In demanding industrial environments, relying on constant manual checks and complex controls is costly and inefficient. The challenge is achieving full automation that adapts to the unique work situation.
Customer Problems (In the Factories):
Unexpected Stops: If a filter broke, the factory might have to stop working right away. This "unscheduled downtime" was very costly.
Wasted Money on Power: Filters were often set to clean themselves even when the factory was closed. This wasted huge amounts of electricity and money.
No Clear View: Managers had no easy way to check the health of all their filters across their entire building quickly.
The Solution
We built ControlPro Connect, a smart web tool that acts as the single control centre for everything. The simple design focused on solving the problems.
Giving Customers Full Remote Control
We created a simple web portal so customers can manage their filters from their office:
Instant Status Check: The main screen shows a simple map of the factory. With a quick glance, managers can see the status, dirt level, and energy use of every filter.
Smart Saving: Customers can easily change filter settings online like setting different work hours for shifts or stopping cleaning cycles during holidays. This helps save power.
Warnings and Help: The system sends clear warning emails if a filter starts performing poorly, telling the staff what they need to do next.
Stop Problems Before They Start: The tool keeps track of the filter’s past performance. It can accurately predict when a filter is about to fail. This allows staff to plan maintenance ahead of time, which completely stops unexpected factory shutdowns.
The Outcome
The new ControlPro Connect system completely changed how Plymovent and its customers work, leading to major savings and less stress.
Huge Energy Savings: By letting customers perfectly match filter activity to their factory's schedule, the system helped factories achieve up to a 40% saving in energy costs.
No More Unexpected Stops: Because staff can plan maintenance based on predictions, factory operations are rarely interrupted by sudden filter failures.
Easy Control: Users now have a simple tool to manage complex machines and optimise their performance from their desk.
Fast Expert Help: The system lets Plymovent experts check the filter online immediately, giving fast help without needing to drive to the factory.
Smarter Decisions: Management can see all the business information in one place for the first time, allowing them to make better, faster decisions for future growth.
Factory Map: The factory map enables users to have a full view of monetising the filtration performance and maintenance all over the factory.
ControlPro Connect is more than IoT software; it’s a smart tool that helps factories run better, safer, cheaper and stretch filter cartridge life.