Will it work with our old machines?
Every generation of equipment talks a different language, and some don't talk at all. We plan for that before the first sensor is ordered.
We engineer software around how your operation actually works.
Industrial IoT development services
For the machines you already have
Start with one breakdown that costs real money. Connect that machine, learn its warning signs, and prove the savings before you touch the rest of the plant. We work with mixed equipment: new CNCs, 20-year-old presses, PLCs from three vendors on one floor.
Line 2 · bottleneckPress 3 · hydraulic pumpWatch
Vibration, mm/s · last 30 daysalert limit
Temperature61 °CCurrent draw+8%Cycles today4,210
Bearing wear pattern. Plan service at the next stop.Create work order
Fair questions
The questions maintenance teams ask before any IoT project
Few maintenance managers are against IoT. Many have seen a project collect months of data and change nothing on the floor.
Is the insight worth the hassle and the money?
Sensors are cheap. Gateways, licenses, setup and upkeep are where the cost sits. If a project can't name the failure it will prevent, it's hard to justify.
Who's going to maintain this?
Many plants have one automation engineer who's already busy keeping lines running. A new platform can't become their second job.
Do we have to open our PLCs to the cloud?
No. Plenty of plants want data to stay on site. We design edge-first when that's the requirement.
The basics
What predictive maintenance is, in short
Signals like vibration, temperature, current draw or cycle counts show a problem developing, so you fix it during planned downtime instead of in the middle of a shift.
What we build
IoT development services: what we build
Machine connectivity
Reads PLCs and controllers over OPC UA, Modbus or MQTT. Older machines get add-on sensors or a small gateway.
Condition monitoring
A live view of each machine's health, with alerts when readings drift outside normal limits.
Predictive models
Learn the pattern behind one specific failure (a bearing, a spindle, a pump) and warn before it happens.
AI for manufacturing →Maintenance work orders
Alerts create work orders in your CMMS or ERP, so the fix gets planned.
Custom ERP →Technician apps
Mobile screens for checklists, photos, parts used and sign-off.
Remote equipment control
Start, stop and adjust settings from a screen, with permissions and an audit log.
Architecture
How the data flows
Our IoT software development services follow a simple path. Local or cloud processing is your choice.
- On the machineSensors and PLCs
- On siteEdge gatewayfilters and buffers data
- Your choiceLocal server or cloud
- For peopleDashboards, alerts, work orders
- Your systemsERP / CMMS / MESERP →MES →
- No cloud? Everything runs on a server inside the plant.
- Control networks stay separated from office IT.
- The gateway only reads data unless you decide it should do more.
Where to start
Predictive maintenance software development starts with one machine
Picking the first asset well matters more than any algorithm. We score candidates on three things:
- 01What an hour of downtime costs, including the line it stops
- 02How often it fails, or how close it came last year
- 03Whether the warning signal can be measured at all
Size the opportunity
Downtime hours / yearCost per hourShare you can avoid
Savings > project cost?Then it goes first.
If not, we'll suggest a different machine, or a simpler fix like a hardwired sensor and an alarm.
Proof
Equipment data and control we've built
Aviation ground support · equipment data on a tabletVestergaard
A tablet app for de-icing crews that reads unit data, runs the treatment step by step, keeps working when the signal drops, and records what was done.
View case study →
Telecom · hardware integration and remote controlBelnet
One platform for an internet provider that talks to network hardware directly: automated connect, disconnect and speed control, plus live equipment monitoring.
View case study →Process
How an IoT project runs
- 01AssessmentWe walk the plant, list machines and controllers, check network and security rules, and choose the first asset with your maintenance team.
- 02Pilot on one machineConnectivity, monitoring and alerts go live, and the data starts building the history a model needs.
- 03a few months inProve itDowntime, repair costs and alert accuracy against the period before.
- 04by savingsScaleMore machines and failure modes, in the order that saves the most.
After launch, someone owns it
Gateways need updates, and models drift as machines age. We support the whole system and adapt it as your equipment changes.
Or run it yourselves
You get the source code, configuration and documentation, and a handover that fits your automation engineer's schedule.
AI helps us analyze sensor data and write code faster. The quality of what we deliver stays our responsibility.
FAQ
Industrial IoT and predictive maintenance FAQ
Can you connect machines that were never built for IoT?
Usually. If the controller exposes data, we read it directly. If it doesn't, clamp-on current sensors, vibration sensors or a simple counter can tell you a lot. For some machines a tablet check by the operator is the sensible answer, and we'll say so.
Do our PLCs have to connect to the cloud?
They don't. The whole system can run on a server in your plant, with the control network kept separate. Cloud is an option, never a requirement.
Which machines are worth instrumenting first?
The ones where an hour of downtime hurts most and failures have a signal you can measure. Bottleneck machines are often the answer.
How much history do we need before predictions work?
Condition monitoring and alerts help from the first week. Predicting a specific failure takes longer, often several months of data and at least a few examples of that failure. Your maintenance logs can shorten the wait.
Can you use the data we already have in SCADA or a historian?
Yes, and it's often the fastest start. We connect to what you have before adding new sensors.
How do you keep the connection secure?
Separated networks, read-only access by default, encrypted traffic, and accounts tied to roles. We follow your IT and OT security rules and document every connection.
What should we ask an industrial IoT development company?
Which protocols and controllers they've worked with, how they handle sites without cloud access, who maintains gateways after launch, and whether you'll own the code. Ask for a pilot plan built around one asset.
What does a pilot cost?
It's driven by the number of machines, the sensors needed and the systems to connect. You get a scope and estimate after the assessment, and you'll see working results at each stage before agreeing on the next.
Which breakdown cost you the most last year?
Start there. Book an assessment and we'll help you pick the first machine, size the savings, and plan a pilot your maintenance team can live with.
Or call us directly:+1 888-438-4988