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Intelligent asset management for heavy industry

Maximise asset performance, reduce unplanned downtime and improve operational resilience across continuous, high-value production plant, with real-time asset intelligence.

Speak to a Meshed expert See how it works
Wireless condition monitoring
IP67 industrial-grade
Additive to your SCADA

Australian industrial IoT, deployed across critical infrastructure since 2015.

A continuous heavy-industry steel and cement works at dusk, fixed plant, furnaces, pipe racks and silos, overlaid with a subtle teal telemetry network
The challenge

Continuous plant, running around the clock, where one failure stops the line

Heavy industry runs continuous and semi-continuous processes where equipment operates around the clock and an unplanned shutdown is extremely costly. The operating environment is harsh, with heat, dust and vibration, and the assets are high-value with long replacement lead times.

Traditional maintenance and monitoring approaches are often reactive, time-based and fragmented, leaving critical assets without continuous visibility. When a kiln, mill, crusher or drive fails without warning, the cost lands as lost production, emergency repairs and safety risk.

Unplanned failures halt continuous production.

Rising maintenance and operating costs.

Higher safety and environmental risk.

What we do

One managed system, from the sensor to the enterprise platform

The platform

One platform, every critical asset

Meshed delivers enterprise-grade asset intelligence that enables industrial organisations to monitor, manage and optimise critical production assets in real time, across equipment health, environmental conditions and operational performance.

Rugged field sensors

For fixed and rotating assets, battery-powered and IP67-rated.

Private, carrier-grade wireless

Long-range LoRaWAN connectivity with no new cabling.

Real-time dashboards and alerting

Live asset health, reporting and configurable alerts.

Enterprise integration

Into SCADA, CMMS, ERP, EAM and business intelligence.

AI-ready

Condition monitoring and predictive maintenance

High-quality data for predictive, condition-based strategies.

By combining rugged field sensors, private LoRaWAN connectivity, data visualisation and enterprise integration, Meshed provides continuous visibility of equipment health across harsh industrial environments built for heat, dust, vibration and around-the-clock duty.

How it works

A simple, step-by-step path to asset intelligence

Meshed simplifies end-to-end asset intelligence across continuous heavy-industry plant. From sensor selection and wireless connectivity to dashboards, analytics and enterprise integration, our proven approach helps operators rapidly connect critical assets, improve visibility, reduce manual inspections and make more informed maintenance and operational decisions.

  1. 1

    Deploy industrial IoT sensors

    Rugged, battery-powered sensors are installed across fixed and rotating assets including motors, drives, pumps, conveyors, crushers, kilns, fans and structural plant, monitoring vibration, temperature, pressure, level and equipment condition.

  2. 2

    Establish secure wireless connectivity

    Sensor data is transmitted securely over long-range, low-power wireless, using LoRaWAN® with cellular or satellite backhaul, moving data off the plant without extensive new cabling or power infrastructure.

  3. 3

    Capture real-time asset data

    Condition, environmental and performance data is collected continuously and delivered securely into cloud analytics, giving greater visibility across distributed and previously unmonitored assets.

  4. 4

    Predict faults before failure

    Dashboards, automated alerts and condition monitoring surface developing faults early, and provide the high-quality, AI-ready data for predictive maintenance before problems result in failure or production loss.

  5. 5

    Integrate with enterprise systems

    Operational data flows into SCADA, CMMS, ERP, EAM and business intelligence systems, so maintenance teams, reliability engineers and operations personnel can manage asset performance and prioritise intervention at scale.

The platform

See machine condition the moment it changes

The Asset Intelligence Platform consolidates data from across the plant into a single, secure view of asset health, environmental conditions and operational performance, so teams can identify emerging issues, automate alerts and act on evidence.

Speak to a Meshed expert
Live vibration and condition-monitoring dashboard showing three-axis OA velocity, peak and RMS acceleration with threshold bands and a detected event spike across rotating plant
Live vibration and condition monitoring across rotating plant, the real operational view.
Unified asset dashboards
Real-time GIS asset mapping
Historical trend and reporting
Alerts for temperature, vibration, pressure and level
Exception, compliance and SLA reporting
Automated maintenance notifications
Secure APIs for enterprise integration

Proven on continuous heavy-industry plant

1,950
hours of unplanned downtime prevented in the flagship steel pilot
53
process interruptions avoided
300
wireless sensors in the initial 12-month pilot

Meshed's asset intelligence is additive. It extends monitoring to the assets your existing systems cannot cost-justify, sits alongside your SCADA and control systems, and does not ask you to rip out or replace what already runs the plant. The wireless layer enhances your operational technology, it does not compete with it.

Where we deliver

Continuous visibility across every critical asset you run

We monitor the health and performance of the assets that keep continuous plant running. Choose an area to see the representative monitoring applications and the operational value delivered.

Rotating equipment & drives

Monitor vibration, temperature and bearing condition across the rotating plant that runs continuous production.

  • Vibration, temperature and bearing condition
  • Motor current and performance
  • Pump and compressor monitoring
  • Conveyor and crusher condition
  • Lubrication and runtime tracking

Predict failures and reduce downtime, maximise production uptime and reduce maintenance costs across motors, drives, pumps, compressors, conveyors and crushers.

Large industrial electric motors and gear drives on continuous plant with a small unbranded wireless vibration sensor mounted on a bearing housing

Process, tanks & pipelines

Track pressure, level, leakage and corrosion across process containment and distribution.

  • Pressure and flow monitoring
  • Tank and vessel level
  • Leak detection
  • Corrosion and asset integrity
  • Water and wastewater quality

Improve safety and asset integrity, and optimise plant performance across tanks, pipelines and pressure vessels.

Outdoor process pipe rack and steel pressure vessels with a small unbranded wireless sensor clamped to a bolted pipe flange

Electrical & structural assets

Watch power quality and structural condition on the assets that keep the plant standing and powered.

  • Power quality and load
  • Switchboard and substation temperature
  • Battery health
  • Tilt, strain and movement
  • Structural vibration and corrosion

Protect critical plant operations and extend infrastructure life across switchboards, substations, silos, stacks and wharves.

Outdoor high-voltage electrical substation beside a tall concrete silo with a small unbranded sensor node on a structural steel member

Environmental & compliance

Continuously monitor the environmental conditions that drive compliance and worker safety.

  • Dust and air quality
  • Weather and noise
  • Water level and flow
  • Emissions and environmental reporting
  • Compliance and exception reporting

Improve compliance and worker safety, and optimise plant performance across environmental and water infrastructure.

Slim environmental monitoring mast with dust and air-quality sensors at the vegetated boundary of a heavy-industry plant

Remote assets & predictive maintenance

Extend visibility to remote assets and turn multi-sensor data into predictive maintenance.

  • Wireless sensing for remote assets
  • Reduced site inspections
  • Multi-sensor analytics with AI
  • Condition-based maintenance
  • Auditable operational data

Reduce site inspections and operating costs, and enable condition-based maintenance strategies across the plant.

Remote pump and generator skid with a pole-mounted LoRaWAN gateway antenna in a wide Australian industrial landscape
Industries

Built for industrial operations across heavy industry

Mining & Resources
Mineral Processing
Manufacturing
Oil & Gas
Chemical Processing
Water & Wastewater
Energy & Utilities
Ports & Bulk Export Facilities
Cement & Quarry Operations
Food & Beverage Manufacturing
A long conveyor drive and rotating plant with several unbranded wireless condition-monitoring sensor nodes mounted along it, linked by a subtle teal data line and no cabling
Case study A steel-mill rotating drive with an unbranded wireless vibration sensor mounted on the bearing cap, warm plant lighting, anonymised with no logos

Predictive maintenance across a global steel operation

A major international steel manufacturer. Continuous steel and port operations across Australia, the Asia Pacific and the United States.

Challenge

The manufacturer needed to prevent unplanned failures across continuous steel and port operations, where a single rotating-equipment failure interrupts production.

Solution

Meshed deployed wireless vibration sensors across motors, drives, hydraulic systems, conveyors and autonomous robotics. Condition data streams into the customer's reliability and predictive-maintenance systems.

Results
  • ✓1,950 hours of unplanned downtime prevented
  • ✓53 process interruptions avoided
  • ✓Scaled from a 300-sensor pilot to more than 4,000 sensors across the Asia Pacific and United States
  • ✓Continuous, auditable condition data in place of manual inspection

"The main benefit is seeing machine failure coming and being able to intervene before you experience a catastrophic failure or loss in production."

A Predictive Maintenance Lead, global steel manufacturer
The difference

Built for continuous heavy-industry plant, not a single control room

Traditional automation, SCADA & telemetry

  • ×Limited to the assets you can justify wiring
  • ×Expensive to scale across the plant
  • ×Primarily reactive maintenance workflows
  • ×High infrastructure and communication cost

The Meshed asset intelligence platform

  • ✓Wireless monitoring for the assets wired systems cannot cost-justify
  • ✓Real-time operational intelligence and AI-ready analytics
  • ✓Rapid deployment, with no shutdown to install
  • ✓Open, additive integration with your existing OT
  • ✓Lower operating cost at scale
The specs

Built on carrier-grade industrial infrastructure

Private & public LoRaWAN®

Private and public wireless network infrastructure.

Carrier-grade managed network

Managed network server with operational support.

IP67-rated hardware

Industrial gateways and sensors built for harsh plant.

End-to-end encryption

Encrypted communications from device to application.

Flexible backhaul

LTE, Ethernet and satellite backhaul support.

Long battery life

5 to 10 years, by sensor type and reporting cadence.

Enterprise integration

SCADA, GIS, ERP, CMMS, EAM and BI platforms.

AI-ready predictive maintenance

High-quality data for condition-based maintenance.

Planning a deployment?

Talk through the right sensors, gateways and integration for your specific assets and plant.

Speak to a Meshed expert ›
Questions

Heavy industry, answered

The questions reliability, maintenance and plant teams ask first. Still need detail on your operation?

Speak to a Meshed expert
Can this integrate with our existing SCADA, CMMS or ERP?

Yes. The platform uses open integration standards and APIs to connect with SCADA, GIS, ERP, CMMS, EAM and business intelligence systems, so data lands where your teams already work.

Will another connected system affect our control network?

No. The wireless sensing layer runs separately from your OT and SCADA environment, with end-to-end encryption. It adds monitoring coverage without touching the systems that run the plant.

Is the hardware rated for harsh plant conditions?

Yes. Gateways and sensors are IP67-rated and built for the heat, dust and vibration of continuous industrial operations.

What assets can be monitored?

Rotating equipment, pumps, compressors, conveyors, crushers, kilns, tanks, pipelines, electrical infrastructure, structural assets and environmental points, across fixed and mobile plant.

How long do the sensors run on battery?

Depending on the sensor type and reporting cadence, many industrial sensors operate for 5 to 10 years on battery power.

Do we need to shut down to install?

No. Sensors are wireless and battery-powered, so they mount without cabling or a production shutdown, and report data within minutes.

Does Meshed provide a managed service?

Yes. We provide end-to-end managed services across network deployment, device management, dashboards, monitoring, analytics and integration.

Validate on one critical asset, then scale across the plant

Kick-start your asset intelligence with a ready-to-deploy Industrial IoT Starter Kit, built for rapid proof of value. Starting with a single gateway and a small number of industrial sensors, you can validate a use case on your worst offenders, capture real-time asset data and demonstrate measurable outcomes before scaling across the plant.

Explore the Industrial IoT Starter Kit
A plant engineer in hi-vis and hard hat reading live asset data on a rugged tablet beside heavy-industry equipment fitted with a wireless sensor

Move beyond reactive maintenance

Continuously monitor critical plant, anticipate failures before they occur and make confident operational and capital-investment decisions that improve safety, reliability and productivity.

Read the predictive maintenance guideSpeak to a Meshed expert

Keep exploring

Wireless vibration monitoring

How wireless condition monitoring avoided more than 1,950 hours of unplanned downtime in heavy industry.

Read the guide

Smart Mining

Asset intelligence across mine, rail, processing and port, another Industrial Automation vertical.

Explore Smart Mining

Private LoRaWAN networks

The Australian-hosted, managed private network your industrial sensors run on.

Discover private networks

Back to Industrial Automation

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