Smart industries need to monitor machines and processes in real time to keep things running smoothly and boost production. Politrace by Polimak is a comprehensive IoT solution that manages process conditioning, machine health, inventory management, and computerized maintenance management technologies from a single source. What sets us apart is how our tech experts and industry specialists combine their knowledge to build one unified IoT solution.
Industry 4.0 and the Industrial Internet of Things (IIoT) are changing the way factories and industrial systems work. Connecting equipment and systems throughout the industrial process gives a clear view of operations, allowing for real-time tracking, better decisions, and improved quality and efficiency. However, it takes deep knowledge and real-world experience to operate, manage, and maintain industrial systems properly. Connecting machines to software isn’t enough unless you know how to read the data in the context of actual processes.
Key Features of Industrial IoT
1. Predictive Quality
Predictive quality analytics uses data from machines, systems, and the environment to identify issues before they happen. It works by finding trends in the data and using machine learning to make predictions about the future. The goal of predictive quality is to find ways to improve product quality in the factory. Predictive quality makes it possible to make smart improvements early in the process.
2. Predictive Maintenance
Predictive maintenance analytics help monitor the real-time condition of machines and systems. This allows operators to take action before a breakdown happens, reducing unplanned downtime. Users can schedule maintenance and keep the right inventory to prevent unexpected breakdowns. Using Politrace predictive maintenance analytics improves worker safety, extends machine life, and helps optimize the supply chain.
3. Condition Monitoring
Politrace lets enables continuously track and check the performance, health, and condition of industrial equipment and systems. Condition monitoring uses sensors to check the temperature, pressure, vibration, vacuum, power consumption, and other factors of various machines. Users can access data from multiple points to monitor both the health and performance of machines in a facility.
Industrial IoT Applications
Politrace, Polimak’s Industrial IoT solution, has many applications in various industries. Here are some key use cases:
1. Silo Level Monitoring and Inventory System
Storage silos are commonly used in various industries to store dry bulk materials. It’s essential to maintain these silos and reserve tanks properly for efficient work. Keeping raw material reserves under control helps industries cut storage costs and stop shortages.
Politrace lets the operators track the amount or weight of dry bulk materials in silos using sensors, providing useful information for managing supplies efficiently. Data collected by the sensors is securely sent to the Politrace monitoring system. Politrace allows users to watch their inventory levels closely from any location at any time via its web interface.
2. Rotary Valve Condition Monitoring
Rotary valves are key components across many industries, helping control material flow in processes that require continuous operation. Politrace enables monitoring of the valve’s operating status with multiple sensors during material discharge.
The sensors collect data on rotor speeds, temperatures and vibrations of the valve body and bearings, power consumption, motor temperature and vibrations, purge air pressure, pressure or vacuum at inlet and outlet ports, and safety protector detections. The data collected is sent to a gateway and then uploaded to the cloud. The Politrace condition monitoring portal lets users view data in real time and make necessary adjustments. Polimak Industrial IoT – Politrace transforms your rotary valves into intelligent smart valves.
3. Dust Collection System Monitoring
Dust collection systems are used in many industries around the world, including cement making, metal work, food production, and chemical processing. Generally, dust collection systems function as auxiliary units designed to shield primary production machinery from damage. System management presents operational challenges, but industrial IoT integration enables better monitoring, cost efficiency, and predictive maintenance to minimize downtime.
Politrace continuously monitors dust emissions at discharge locations and provides alerts when concentrations approach or surpass regulatory thresholds, enabling swift intervention. Additional parameters that can be monitored include filter pressure differentials, energy consumption, and the mechanical condition of system components. Real-time monitoring through industrial IoT allows for immediate adjustments, helping optimize the overall performance of the system.
4. Quality Improvement and Preservation
Maintaining consistent product quality requires continuous monitoring of critical parameters, which can be reliably achieved through sensor-based systems. Sensor signals are transmitted to the Politrace condition monitoring portal, enabling management to receive immediate alerts when quality thresholds are exceeded and to track conditions in real time.
For example, in food processing operations, variables such as temperature and humidity are critical to ensuring the quality of the final product. In such cases, exceeding temperature or humidity thresholds triggers immediate notifications to management, enabling timely interventions to maintain product quality.
5. Production Line Performance Monitoring
Numerous plug-and-play sensors are available for comprehensive monitoring of machinery such as CNC units, hydraulic presses, rolling equipment, and packaging lines. These sensors capture real-time metrics including temperature, vibration frequencies, humidity levels, start-stop events, fault conditions, energy consumption, and press cycle counts. Data is securely transmitted to the Politrace condition monitoring platform for continuous data analysis and system diagnostics.
The Working Principle of Politrace
PICTURE
How We Provide Solutions by Politrace
1. Process Analysation
Our engineering team has the expertise to conduct a detailed analysis of your machinery and production processes based on defined operational goals. By collaborating with your operations team, we identify essential process metrics—such as projected output—and determine optimal sensor placement and data capture points.
2. Correct Architecture Determination
Ensuring uninterrupted service relies on the correct configuration of edge devices such as sensors and gateways, as well as secure and scalable server networks. Key considerations include geographic location, existing network infrastructure, safety requirements, and connectivity options. Our engineering team can evaluate your production systems and deliver a tailored, fault-tolerant architecture.
3. Supplying IIoT Platfroms and Equipment
We offer easily installable sensors and gateways, complete with the necessary mechanical and electrical interfaces. Customers may also integrate third-party sensor and gateway brands of their choice. The Polimak IIoT platform is designed for user-friendly operation and streamlined control.
4. Asset Management Service
Our Industrial IoT platform integrates an asset management system that supports structured assignment of assets to operational teams. Users can schedule maintenance, upload and access relevant documentation, and attach visual references. The system enables real-time, remote access and provides detailed control over each asset within the plant environment.
5. Data Visualization and Analytic Service
The Polimak Industrial IoT platform unlocks the potential of big data analytics, equipping facilities with secure, user-friendly capabilities for business intelligence, predictive quality control, maintenance forecasting, and AI-driven insights.
Advantages and Key Benefits of Industrial IoT
Polimak’s Industrial IoT solution, Politrace, ensures delivery of precise data in real time, allowing users immediate access to necessary information for accurate decision-making. Some of Politrace’s advantages include:
• Enable predictive and preventive maintenance to minimize unexpected failures
• Continuous machine health and condition monitoring
• Immediate alerts and notifications for anomalies
• Enhance overall machinery performance
• Lower maintenance and repair costs
• Conduct detailed downtime analysis to optimize machine utilization
These valves are typically actuated by pneumatic actuators and are used to automatically open and close the product flow to discharge material to downstream equipment.
Installed below silos or hoppers, these valves are used for maintenance operations of equipment such as rotary valves, screw feeders, etc., that are positioned below the butterfly valve.
These valves are typically actuated by pneumatic actuators and are used to automatically open and close the product flow to discharge material to downstream equipment.
In this design, the butterfly valve is sandwiched between two flanges. Rubber sealing at both faces of the valve provides a tight seal between the flanges and the wafer butterfly valve.
One side of the valve has a bolted flange connection, while the other side features a built-in short pipe designed for fixing a flexible sleeve.
These valves have bolted flange connections on both sides, making them suitable for installation on silos, hoppers, screw feeders, and similar applications.
Bulk tanker trucks or open trucks can be filled with powdered materials delivered within FIBC bags. These systems generally consist of bulk bag discharging station, mechanical or pneumatic conveyor and loading bellow. Big bag discharge station transfers the bulk solid from big bag to conveying system. Conveying system transfers it to truck loading area. And loading bellow is used to fill tanker truck without any dust emission. Since truck loading operations are done within limited time, high capacity big bag discharge systems and bulk material conveying systems are used. For short distances, screw conveyors are preferred to transfer material from big bag discharge station to truck loading chute. For long conveying distances, pneumatic conveying systems provide better service. There may exist a storage hopper or silo above bulk truck loading bellow to compensate material flow between inlet and outlet. Bulk bag discharge and truck filling systems have automatic control system that monitors product level in truck and operates all equipment accordingly. Optional weighing system can be added to measure the amount of material that is filled to truck.
Big bag discharge systems can deliver dry bulk solids in powder and granular form to weighing and batching systems. The loading hopper of the weighing system should remain full during dosing and batching. Big bag discharge systems can monitor the product level in the loading hopper and maintain a constant level automatically. Depending on the dosing speed and conveying distance, mechanical conveying systems or pneumatic loading systems may be used. Dust collectors can be employed to prevent dust emissions during hopper loading, especially for materials with high dust content.
Dry bulk packaging systems are used to fill powdered or granular materials into bags, drums, jars, sacks, etc. Bulk materials delivered in big bags must be transferred to packaging machines without interruption. The loading hopper of the packaging system should remain full during the filling and packaging process. Big bag discharge systems can monitor the product level in the loading hopper and maintain a constant level automatically. Depending on the packaging speed, mechanical conveying systems or pneumatic loading systems can be selected. Dust collectors can be used to prevent dust emissions during hopper loading, especially for materials with high dust content.
Mixer automation systems are used to mix dry bulk solids according to specific recipes. Raw materials delivered in FIBC bags can be transferred to mixing units through a combination of conveying equipment and bulk bag discharge systems. Depending on the type of application, pneumatic conveying or mechanical feeding systems can be used to fill mixers. Big bag discharge stations can be manufactured with built-in dosing systems. The amount of raw material to be loaded into the mixer is automatically controlled with the help of a weighing and dosing system. Dust collectors can be used to prevent dust emissions during the mixer filling process.
Bulk material stored in big bags can be automatically filled into small bags. Big bag discharge systems come with optional built-in bag filling units. For low filling capacities, these units are installed below the big bag discharge hopper, providing a practical and cost-effective solution. Both big bag discharging and bag filling operations can be handled by a single, compact system. For higher bag filling needs, bag filling machines are installed near the bulk bag discharge stations. Pneumatic conveying systems or mechanical conveyors can be used to transfer bulk material from the FIBC bag discharge station to the bag or sack filling system.
Mechanical conveyors can be used for silo loading from big bag discharge stations. Screw feeders, bucket elevators, rotary valves, or chain conveyors are connected to big bag discharge stations to fill silos. The selection of conveying equipment directly depends on the conveying distance, height, transferred material, and capacity. Bucket elevators are preferred for high silos, while screw feeders are preferred for shorter silos and short distances. The big bag discharge system can be installed on top of the silo for faster filling. In this case, rotary valves or butterfly valves are better choices as they provide simple flow control. Dust collection systems may be required depending on the dust content of the bulk solid. During silo loading, air content in the silo escapes to the atmosphere and carries some dust along with it. Vacuum fans and jet filters in dust collectors prevent dust emissions into the environment. The collected dust is sent back to the silo, thus preventing product loss.
Pneumatic conveying systems installed after bulk bag discharge units transfer bulk material through conveying pipelines to fill silos. This configuration is useful in applications where high transfer rates and long conveying distances are needed. In production lines where raw materials are stored in warehouses far from storage silos, bulk bag discharge stations can be installed close to the warehouses, and pneumatic conveying systems are used to fill silos from long distances. This design reduces the need for forklifts and cranes for bulk material transfer on the production site and increases overall efficiency.
Pneumatic conveying systems used for silo loading utilize blower pumps or compressors. Motor power, pipeline diameter, and equipment selection depend on the type of bulk material, transfer distance, silo height, and transfer capacity. Level sensors, jet filters, and other equipment are installed on storage silos to ensure the proper operation of the silo filling system.
Pneumatic conveying systems installed after bag dump units transfer bulk material through pipelines to fill silos. This configuration is ideal for applications requiring high transfer rates and long conveying distances. In production lines where raw materials are stored in warehouses far from storage silos, bag dump stations can be installed close to warehouses, allowing pneumatic conveying systems to transport materials over long distances. This design reduces the excessive use of forklifts and cranes for bulk material transfer within the production site, improving overall efficiency.
Pneumatic transfer systems used for silo loading utilize blower pumps or compressors. Motor power, pipeline diameter, and equipment selection depend on factors such as the type of bulk material, transfer distance, silo height, and transfer capacity. Level sensors, jet filters, and other equipment are installed on storage silos to ensure the proper operation of the silo filling system.
Mechanical conveyors can be used for silo loading from bag dump stations. In this configuration, screw feeders, bucket elevators, rotary valves, or chain conveyors are connected to bag dump stations to fill silos. The selection of conveying equipment depends on factors such as conveying distance, height, material properties, and capacity. Bucket elevators are preferred for high silos, while screw feeders are ideal for shorter silos and short distances. Bag dump systems can be installed on top of the silo for faster filling. In such cases, rotary valves or butterfly valves are better choices as they provide simple flow control.
Dust collection systems may be required depending on the dust content of the bulk solid. During silo loading, air inside the silo escapes to the atmosphere, carrying dust particles with it. Dust collectors equipped with a vacuum fan and jet filter capture airborne dust. The collected dust is returned to the silo, preventing product loss and ensuring a cleaner environment.
The inlet skirt is an optional feature designed to extend the lifespan of the flexible connector sleeve. Its upper portion is attached to the outlet port of the upstream equipment and extends down into the bin activator’s inlet port. The primary function of the inlet skirt is to serve as a protective shield, safeguarding the flexible connector seal from wear and damage.
A vibratory motor is externally mounted to the bin activator. When powered, the motor generates vibrations that facilitate a steady flow of dry bulk materials within the system. Depending on the application requirements, one or two vibratory motors can be installed externally.
To accommodate a bin activator, the cone of a silo must be shorter than usual, resulting in a wider outlet. A flange supplied with the bin activator is separately welded to the silo’s outlet, slightly above the opening, at the production site. Once installed, the vibrating bin discharger is securely bolted to the flange, ensuring a stable and reliable connection.
Special spring suspension links and an engineered polymer seal work together to create a flexible connection between a vibrating bin discharger and the equipment positioned above it.
The proper design and installation of the polyurethane seal prevent it from slipping off and ensure a secure seal, eliminating the risk of dry bulk material leakage. Additionally, the seal offers high stress resistance and long-term durability, withstanding stresses caused by motor vibrations, pressure conditions, and other operational factors.
Externally installed spring suspensions provide full resilience to the vibrations of the cone head. They ensure that the generated vibrations affect only the cone itself rather than the upstream equipment structure.
An internally tapered, conical-shaped baffle plate is positioned at the center of the bin activator’s diameter. The baffle is rigidly attached to the equipment body using structural steel components. It facilitates bulk material flow from upstream equipment by directly inducing vibrations into the material.
A secondary deflector plate reduces the weight of the bulk material in the lower portion of the bin activator by acting as a wedge beneath the material, directing it around the areas adjacent to the cone’s surface.
Polimak baffle plates are available in various configurations, including convex and cone plates, and in different angles (15°, 30°, 45°, or even 60°) depending on the flow characteristics of the handled bulk material and the specific application requirements.
