ProPlantPredictive Maintenance Platform
Improve plant reliability with real-time monitoring and AI driven insights
ProPlant helps you reduce downtime, enhance operational efficiency, improve safety while optimizing performance.
Also explore: Knowledge & Training Platform
80-90% training cost reduction • 3-6 month payback • No manual documentation
The Challenge
The Hidden Cost of Equipment Failure
Unscheduled downtime costs Fortune 500 companies $1.4 trillion annually—11% of total revenues
ProPlant's Predictive Maintenance Platform
Transform from reactive to predictive maintenance with AI-powered monitoring and analytics
Real-Time Monitoring
Continuous tracking of critical parameters—temperature, pressure, flow, vibration, and energy consumption. 24/7 visibility into every critical asset across your facility.
AI-Powered Predictions
Advanced machine learning models analyze historical trends and current data to predict failures weeks in advance. Schedule maintenance proactively, not reactively.
Intelligent Alerting
Smart alarm systems prioritize critical issues over false alarms. Actionable insights delivered to the right people at the right time for immediate response.
Real-Time Monitoring
Monitor Every Critical Asset Across Your Facility
24/7 Eyes on Your Operations
ProPlant gathers data from sensors installed throughout your facility. Our platform continuously monitors critical parameters, providing complete visibility into equipment health and performance across all your assets.Multi-Parameter Tracking
Temperature, pressure, flow rate, vibration levels, energy consumption, and more—all in one unified dashboard.
Anomaly Detection
AI algorithms automatically identify deviations from normal operating conditions, flagging potential issues before they escalate.
Real-Time Alerts
Instant notifications to operators and maintenance teams when parameters exceed thresholds or anomalies are detected.
Predict Failures Before They Happen
By analyzing historical trends and correlating them with real-time data, ProPlant predicts potential equipment failures days or weeks in advance—giving you time to plan and prevent costly unscheduled downtime.Machine Learning Models
Advanced algorithms find patterns in your operational data to predict equipment failures with high accuracy.
Historical Trend Analysis
Analyze years of operational data to understand degradation patterns and predict remaining useful life of assets.
Proactive Maintenance Scheduling
Schedule interventions at optimal times to minimize downtime and extend asset lifespan, reducing emergency repairs by up to 70%.
Enterprise-Grade Features for Industrial Operations
Beyond basic monitoring—ProPlant delivers comprehensive analytics, customization, and integration capabilities
Customizable Dashboards
Tailor dashboards to your specific needs. Visualize KPIs, trends, and alerts for different roles—from operators to executives. Rich data visualization helps identify issues at a glance.
Seamless Integration
Connect with your existing DCS, SCADA, historians, and ERP systems. ProPlant integrates seamlessly with legacy infrastructure—no rip-and-replace required.
Cloud & On-Premise Options
Deploy in the cloud, on-premise, or hybrid configuration based on your security and compliance requirements. Full data sovereignty and control.
Scalable Architecture
Start with a single unit or facility and scale to enterprise-wide deployment. Monitor thousands of assets across multiple sites from one centralized platform.
Key Benefits
Transform Your Maintenance Operations
ProPlant's predictive maintenance platform delivers measurable ROI across your operations
Reduce Costly Downtime
Prevent unexpected equipment failures that disrupt production. Early anomaly detection ensures uninterrupted operations and maximizes asset availability.
Lower Maintenance Costs
Shift from expensive reactive repairs to planned, cost-effective maintenance. Reduce emergency callouts and overtime by up to 60%.
Extend Asset Lifespan
Optimize maintenance schedules based on actual equipment condition, not arbitrary calendars. Reduce wear and tear, extending critical equipment life by 20-30%.
Improve Safety
Monitor safety-critical equipment continuously. Early warning of potential failures prevents dangerous situations and ensures regulatory compliance.
Optimize Resource Utilization
Better maintenance planning means better resource allocation. Reduce spare parts inventory and optimize maintenance crew schedules.
Increase Operational Efficiency
Data-driven insights enable continuous improvement. Identify inefficiencies, optimize processes, and make informed decisions backed by real operational data.
Support for Sustainability Goals
Optimize energy usage and reduce waste. ProPlant helps achieve sustainability targets by identifying inefficient equipment operation and energy consumption patterns.
Mobile Access
Access critical information anywhere, anytime. Mobile-responsive dashboards and alerts keep your team connected to plant operations 24/7.
Historical Data Analytics
Leverage years of operational data for insights. Identify long-term trends, benchmark performance, and continuously improve operations.
Competitive Advantages
Why Choose ProPlant Predictive Maintenance?
Industry-leading technology meets operational excellence
Our AI is trained specifically for petrochemical, chemical, and manufacturing environments—not generic models adapted from other industries.
Get up and running in weeks, not months. Our proven deployment methodology ensures rapid time-to-value with minimal disruption.
Customers typically see 3-6 month payback through reduced downtime, lower maintenance costs, and improved asset utilization.
Your operational data is critical. We employ bank-level encryption, role-based access control, and comply with industrial security standards.
Our team includes industrial engineers and data scientists who understand your challenges. Get expert guidance throughout implementation and beyond.
Regular platform updates bring new capabilities and improvements. Benefit from the latest AI and analytics advancements automatically.
Purpose-Built for Process Industries
Unlike generic enterprise solutions, ProPlant is designed specifically for petrochemical, chemical, and manufacturing operations
| Capability | ProPlant | IBM Maximo | GE Predix | SAP PM | Siemens |
|---|---|---|---|---|---|
| P-F Curve Analysis Three-phase degradation modeling with RUL prediction | Advanced | Basic | Limited | | Partial |
| Multi-Parameter Health Scoring Composite health index across process parameters | Built-in | Add-on | | Custom | |
| Process Industry Specialization Pre-configured for chemical, petrochemical, pharma plants | Native | Generic | Industrial | | Mixed |
| Integrated Knowledge Repository 2-way sync between predictive insights and operational knowledge | Native | | | Via API | |
| 5-Stage Alert Matrix Criticality-based degradation stage monitoring | Built-in | Custom | | | Basic |
| AI-Powered Natural Language Queries "Ask ProPlant" - conversational insights and analysis | Integrated | | | Limited | |
| User Experience & Ease of Use Intuitive interface requiring minimal training | Excellent | Moderate | Complex | Steep Learning | Moderate |
| Customization for Specific Needs Flexible configuration to match unique operational requirements | Highly Flexible | Limited | Configurable | Rigid | Moderate |
* Based on publicly available information and industry analyst reports (2024-2025)
Proven Results from Industry Research
Data from U.S. Department of Energy and McKinsey research shows predictive maintenance delivers exceptional ROI
Fortune 500 Impact
With full adoption of predictive maintenance, Fortune 500 companies can save:
Ready to prevent failures before they happen?
Let's discuss how ProPlant can transform your maintenance operations.