Know when your filter really needs to be replaced.
From time-based to condition-based maintenance: Monitor your filters in real time, avoid unplanned downtime, and save money.
This is exactly where heating jackets come in: they reliably keep the medium flowing within the valve or pipe section, thereby stabilizing the process.
For applications involving toxic or environmentally hazardous media, an additional safety feature is included: leak containment jackets (double jackets) can contain leaks in a controlled manner and, optionally, assist with detection.
up to 75%
up to €5,500
100% ROI
7 days
This solution is being developed in collaboration with our technology partner, ifm electronic, and is based on the proven IIoT platform moneo.
The problem: Scheduled maintenance is expensive—in both directions
Filters are the heart of many production facilities—and yet they are also the most frequently underestimated wear component. In practice, they are replaced at fixed intervals, regardless of how dirty they actually are.
The result: either replaced too early (waste of resources, unnecessary downtime) or detected too late (production defects, machine damage, costly breakdowns).
Typical consequences of undetected filter contamination:
- Quality defects
- Overheating due to reduced cooling capacity
- Damage to the hydraulic and lubrication systems
- Unplanned production stoppages
- Violations of TA-Luft regulations
Our solution: Condition monitoring for all filter types
In partnership with ifm electronic, we offer a comprehensive monitoring system for air, water, and oil filters—suitable for use in the pharmaceutical, chemical, automotive, electronics, and food industries.
Air filter
Measurement of pressure differential before and after the filter. Compliance with TA-Luft requirements; protection of employees and exhaust systems.
€900 in savings per year
Water filter
Monitoring of cooling circuits and heat exchangers. Prevents overheating damage caused by clogged fine filters.
up to 75% fewer changes
Oil filter
Protection of hydraulic and lubrication units. Early detection prevents consequential damage costing up to €5,500.
ROI starting at 2.5 years
Here’s how the solution works
Four components make up the complete system—from the sensors to automated maintenance notifications:
Step 1
IO-Link Sensors
Step 2
IO-Link Master
Step 3
moneo Platform
Step 4
AI Forecast & Alert
Business Cases – What Are the Concrete Benefits?
The following values are based on actual customer projects carried out by ifm electronic:
| Filter type | Optimized filter replacement | Avoided downtime costs | ROI period |
| 🌬️ Air filter | €900Annual savings through targeted replacement | up to €5,000prevented damage caused by filters that were not replaced | 100% for ages 1.8 and up |
| 💧 Water filter | 75 %Fewer filter changes · Save €800 per year | —Unplanned production downtime prevented | 100% for children ages 2.5 and up |
| ⚙️ Oil filter | €300Annual savings through targeted replacement | up to €5,500avoided repair costs | 100% for children ages 2.5 and up |
Source: ifm electronic gmbh – Average values based on actual customer projects. Individual results may vary.
Your advantages at a glance
- Maximum machine uptime
No unplanned downtime due to clogged or defective filters - Cost-Optimized Maintenance
Filters are replaced exactly when needed—not too early, not too late - Planning certainty
7 days’ lead time for optimal staffing and material planning
‘s AI-powered remaining-life prediction: moneo LifetimeEstimator learns the specific contamination patterns of your filters- SAP PM & ERP Integration
Automatic maintenance orders via the SFI interface in SAP - Sustainability
Conservation of resources through filter replacement based on actual needs, reduced environmental impact
Interested? Get in touch with us.
We’ll work with you to identify which filters in your system would benefit most from smart monitoring—and show you your specific ROI.
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