A global life sciences and chemical manufacturing company partnered with Ecolibrium to enhance operational reliability through AI-powered industrial equipment monitoring and chiller optimisation for manufacturing plants. By deploying Ecolibrium SmartSense across three facilities and 30 production units, the organisation achieved real-time visibility, reduced downtime, and improved asset performance through predictive insights and automated monitoring. 

Outcome Summary 

• Reduced downtime and energy loss through predictive fault detection. 

• Improved reactive maintenance using real-time alerts. 

• Enhanced asset performance through centralised monitoring and root-cause analysis. 

The Challenges 

The company faced recurring issues with chiller fouling, high energy consumption, and inefficient manual data tracking in their manufacturing plants. Production relied on stable temperatures, yet fouling in evaporators and condensers led to tripping, poor heat exchange, and increased operational costs. In addition, teams lacked a unified view of asset performance, and maintenance was largely reactive. Which led to delaying interventions and increasing the risk of equipment failures in manufacturing plants. 

The Solution 

Ecolibrium SmartSense was deployed with 1,200+ sensors across 30 production units at three sites, enabling real-time monitoring of chillers, transformers, and other energy-intensive equipment. The system offered automated anomaly detection, KPI dashboards, and instant alerts. Ecolibrium SmartSense’s AI-based alerts tracked temperature deviations, flow anomalies, and load imbalances, helping maintenance teams detect faults early and optimise operations. The platform also provided detailed chiller performance reports and enabled energy planning through Ecolibrium SmartSense’s widget-based load management tools. 

Analysed 1200-1300 data points across 30 production units. Monitored chillers, turbines, transformers, energy meters & vapour absorption machines (VAM) assets to resolve the challenge. 

The Outcome 

The Ecolibrium SmartSense platform reduced unplanned downtime and energy losses by detecting early signs of fouling and equipment stress. Real-time alerts improved the speed and accuracy of maintenance responses, transforming reactive workflows into predictive operations. Maintenance teams were now equipped with data to address problems before they escalated, thus leading to enhanced productivity and reduced energy wastage across the plant network. 

The Impact 

Ecolibrium SmartSense detected evaporator and condenser fouling using AI-based alerts for anomaly, allowing for faster interventions. The platform reduced energy consumption through automated load variance tracking and helped optimise transformer operations via real-time OTI/WTI monitoring. Unbalanced load distribution and chiller tripping causes were quickly identified, significantly reducing downtime. Centralised visibility across assets and predictive insights allowed the operations team to enhance reliability, lower operating costs, and preserve long-term asset health. 

Want to reduce downtime and improve asset reliability across your plants? 

Discover how Ecolibrium SmartSense can help you detect faults early, cut energy loss, and streamline operations with real-time intelligence. Book a demo now.