SERVICES

Plant Monitoring and Industrial IoT

Equipment monitoring continuously tracks the status and data of machines and production facilities and displays them in dashboards and alerts. torck, based in Maxhütte-Haidhof near Regensburg, develops customized software for this purpose, ranging from sensor retrofits on existing machinery to data platforms using OPC UA and MQTT, all the way to integration with ERP and control systems. With over 100 employees at our locations in Maxhütte-Haidhof near Regensburg, Vienna, and Rabat, we operate independently of any specific manufacturer and use open standards. The OPC Foundation provides more information about the OPC UA open standard.

Plant Monitoring as a Service: From Retrofit to Data Platform

We work with you to develop the solution. We recommend the right sensors for your project, handle the integration of your systems, and build the underlying data platform, all vendor-neutral, using open standards, from pilot to full-scale operation.

RETROFIT & SENSOR TECHNOLOGY

Retrofit & Sensor Integration

We digitize existing machines without modifying the control system, whenever possible. Retrofitted sensors measure temperature, vibration, flow, energy consumption, and other conditions. Connectivity is provided via LoRaWAN where wiring is not possible, and via Modbus where existing field devices provide data. This generates machine data from systems that never had an interface. Learn more about software for mechanical engineering: Software for Mechanical Engineering.

DATA PLATFORM

Data Platform & Integration

Raw data alone isn't enough. We build the data layer in between. OPC UA connects modern control systems, MQTT transmits the data, and Node-RED implements the data flows. This is followed by a time-series database, dashboards, and alerts, integrated into ERP, control systems, or MES via open APIs. For energy management and consumption monitoring: Jouvoli, our energy monitoring platform.

Here's how we do it

1. Pilot: few systems, fixed budget

We start with one or a few systems: sensors, data connectivity, and an initial dashboard with alerts. Within weeks, you’ll have real data and a solid cost basis for the rollout.

2. Rollout: Integration Instead of a Siloed Solution

Whatever proves successful in the pilot, we roll out on a larger scale: additional systems and locations, and integration with ERP and control systems via open APIs instead of proprietary connectors.

3. Operations: System Instead of Project

We handle hosting or on-premises operations, updates, and security patches, and continue to develop the solution as new systems or requirements arise.

The data is available, just not where it's needed.

Most production facilities have long been generating data such as temperatures, pressures, status information, and meter readings. Yet little of this data is actually utilized: Existing machines without interfaces remain a “black box”; siloed solutions prevent a comprehensive view; and closed systems tie your data to a single provider. This can be resolved without replacing your equipment, using open protocols and software that’s tailored to your system.

Condition Monitoring & Predictive Maintenance

First the condition, then the forecast. Condition monitoring shows you how your equipment is actually performing, based on thresholds, trends, anomalies, and alarms. Building on this data, predictive maintenance is implemented where it makes the most sense: maintenance based on condition rather than a schedule. We’ll also tell you where a simple threshold alarm is sufficient and no ML model is needed.

We work according to proven standards and expertise

Projects in Controlled Environments (Version 2)

Information Technology Infrastructure Library

BPM: Business
Process Management

Project Management/Software Development

PECB ISO 50001 Lead Implementer

Scrum.org Professional Scrum Facilitation Skills

SAFe POPM (Product Owner/Product Manager)

Capability Maturity Model (more commonly known as CMMI)

iSAQB Certified Professional for Software Architecture (CPSA)

A portion of our technical certifications and credentials are maintained through the individual accreditations of our specialists.

Frequently Asked Questions About Plant Monitoring

Does this also work with older machines that don't have an interface?

Yes. That’s what retrofits are for. Retrofitted sensors monitor external conditions (such as temperature, vibration, power consumption, and operating status) without interfering with the machine’s control system. Depending on the location, the connection is established via LoRaWAN or Modbus. Therefore, the age of the machine is rarely the actual problem.

How much does a retrofit project cost?

That depends on the number of systems, the sensor technology, and the level of integration. There is no standard flat rate. We typically start with a limited pilot project involving one or a few systems with a fixed budget. Afterward, you’ll have real data, a reliable cost basis for the rollout, and a system that’s already up and running.

Cloud or on-premises?

Both, including hybrid solutions. Some customers want to host their data in-house, while others prefer not to operate their own servers. We build using technologies that run in both environments. The choice depends solely on your requirements regarding data sovereignty, IT operations, and connectivity. We provide open advice on this matter without recommending any specific platform.

How long does a pilot project last?

A typical pilot project involving a small number of systems, sensors, data connectivity, and an initial dashboard with alerts takes several weeks. The exact duration depends on the accessibility of the systems and the delivery times for the sensors. You will receive a specific timeline after the initial consultation, usually within a few days.

What protocols and interfaces do you support?

At the field level: LoRaWAN and Modbus; for control system integration: OPC UA; for data transmission: MQTT and REST. We implement data flows using Node-RED, among other tools. For ERP, MES, or control system integration, we use the existing interfaces. If something is missing from the list, please ask us. Protocol integration is at the core of our work.

Are we tied to torck afterwards?

No. We rely on open standards and open formats. The data belongs to you, and the architecture is documented. You can continue to operate the system yourself or hand it over to another partner. Whether you stay is determined solely by the work itself. There’s no need to be tied to us.

From the blog

→Implementing Plant Monitoring: Questions to Consider Before Selecting Software →Predictive Maintenance: What It Can and Cannot Do →From Sensor to Dashboard: The Data Chain in Plant Monitoring →Vibration Analysis: Monitoring Bearings, Pumps, and Motors →Retrofit Instead of Buying New: Digitizing Existing Systems →Connecting OT and IT: Integration Patterns Without Production Risk →Energy Monitoring: 5 to 25 Percent Savings Through Transparency →EU Data Act: Access to Machine Data as a Requirement and an Opportunity →NIS2 in Production: Demonstrating OT Security

All posts in the "Plant Monitoring" category →

CONTACT

Let's talk about your investments.

Tell us about your use case: what systems, what data, and what your goal is. We’ll provide you with an assessment of what a pilot project can achieve, how much it will cost, and what its limitations are. No strings attached, and no endless slide presentations.