four zones · continuous monitoring.
Each zone of your injection plant has different risks: injection machines, hoppers and dryers, hydraulics, CFE GDMTO energy. One platform covers all four. Your team operates everything from the web dashboard, mobile app, or WhatsApp.
injection machines
Each machine with current-signature analysis · detects worn bearings, degrading servos, critical motor over-consumption. Cycle telemetry: close time + pressure + mold temperature correlated.
hoppers and dryers
Temperature + humidity sensor on granulate hoppers (target <0.05% MS for ABS, <0.1% for PP). Dryer room with learned baseline. Alert before the first box of bubbled parts leaves the machine.
hydraulics
Hydraulic oil pressure + temperature sensor with per-machine baseline. Early detection of damaged seal pump, clogged filter, or internal leak. Scheduled maintenance instead of 12-hour downtime at $12K/hr.
CFE GDMTO energy
Three-phase meter on main panel + per-machine sub-metering · power-factor analysis · contracted-demand management. Capacitor bank justified with data · ~50-day payback.
Out of scope: machine process control · MES · ERP. AstreaIoT does not replace them; if your MES or ERP needs cycle or energy-per-unit data, we integrate via Custom Integration.
what we protect · what we prevent.
- +Worn-bearing detection 2-4 weeks before failure · scheduled change instead of 12-hour downtime
- +Hopper humidity in spec before the first rejected box · OEM lots protected
- +Hydraulics with learned baseline · seal replaced in scheduled maintenance
- +Capacitor bank justified with real data · approximate payback in 50 days
- +kWh-per-unit-produced efficiency visible per machine and shift · ESG-ready OEM compliance
- ✕12-hour JIT downtime with OEM client downstream · one hour costs tens of thousands
- ✕Whole lot rejected by OEM from out-of-spec hopper humidity
- ✕Permanent CFE GDMTO surcharge from low power factor
- ✕Emergency hydraulic repair vs scheduled maintenance · several times the cost
- ✕Contracted-demand overrun in peak hours · surcharge on $420K/month bill
ten use cases · four critical areas.
for the plant manager.
Plant Manager + Operations Director. Three cases · unexpected critical-motor failure, cycle telemetry detects deviating machine, hydraulics with degrading seal. Each machine with current-signature analysis + learned baseline.
for the quality director.
Quality Director + OEM Quality Director. Two cases · out-of-spec hopper humidity generates bubbled parts, out-of-range dryer room invalidates day production. Alert before the first box leaves.
for the operations director and CFO.
Operations Director + CFO. Three cases · low power factor penalizes $420K/month bill, peak demand near contracted limit, kWh-per-unit-produced efficiency by shift and machine. CFE GDMTO with continuous sub-metering.
for the maintenance lead.
Maintenance Lead + Safety Officer. Two cases · electrical-room overheating, generator does not start on blackout. Automatic STPS compliance with continuous record.
three compliances · one platform covers all three.
For multi-plant operators (3-12 plants), national dashboard with per-plant efficiency ranking — identifies systemic patterns before the OEM identifies them.
from sensor to report · every five minutes · without human intervention
Five steps. They run in parallel across all your sites, all the time. When something crosses a threshold, the flow completes in under five minutes — alert delivered, response logged, inspector-ready evidence captured.
measure
Sensors measure temperature, humidity, current, door-open, leak and other magnitudes every five minutes — no operator required.
detect
The system compares each reading against the threshold configured per recipe · per site · per equipment. Threshold crossing triggers the flow.
alert
The alert routes to the right person via WhatsApp, email or push · per role and schedule configured.
respond
The operator acts from the dashboard or mobile app. The corrective action goes into an immutable log with timestamp + signature.
audit
Everything becomes part of the audit package · time series, critical events, corrective actions, NOM report ready in two clicks.
Five steps · no manual operators · no paperwork · no gaps.
five phases · per plant.
site survey per plant
1 dayTechnical visit + inventory of injection machines, hoppers, hydraulics and CFE panel · STPS checklist · OEM SLA identification.
physical installation
3-4 dayscurrent meter per critical machine + temperature/humidity sensors on hoppers + oil pressure/temperature sensor + panel three-phase meter · no operational shutdown.
configuration + calibration
2 daysPer-machine thresholds · baseline learned in 5-7 days · OEM report templates · WhatsApp alerts configured per role.
team training
1 dayPlant Manager + Maintenance Lead + Quality + Operations · each role trains on their alert and report flow.
30 days of support + first monthly report
30 daysAstreaIoT specialist available · first monthly report delivered · first OEM audit backed by continuous data.
For multi-plant operators: after the first pilot plant, phases compact to 7-10 days per plant with monthly waves.
common questions · before the quote.
does it work with injection machines from any vendor?
Yes. Current-signature analysis is done on external current meter on the motor · without touching the machine process control · without operational shutdown. Compatible with Engel, Krauss-Maffei, Husky, Sumitomo and others.
how are hopper humidity sensors calibrated?
Sensors calibrated in an accredited laboratory before deployment. Validity tracked per equipment in the dashboard. Recalibration every 12 months · we keep the calendar.
does it integrate with the plant MES or ERP?
Yes · via Custom Integration. We connect you to SAP, Oracle, Microsip, proprietary MES or a custom system. Cycle, energy and operating-hours data arrive directly in your central system.
how long does it take to assemble an OEM audit report?
Three clicks. The system assembles it automatically with the selected 30 days, per-OEM client template, Quality Manager signature included. PDF ready to print or email in under one minute.
what happens if the plant internet goes out?
The gateway has 32-hour backup and local buffer. Sensors keep recording · everything syncs on reconnect. Included cellular backup takes over if the outage prolongs.
does current-signature analysis detect servos?
Yes · servo, main motor, hydraulic pump, any rotating equipment. The algorithm learns the normal signature in 5-7 days and alerts when it detects degradation 2-4 weeks before failure.
what happens if a machine goes to maintenance?
Sensors are portable · they are removed and mounted on the backup machine in 15 minutes. The system automatically maps the new assignment. No penalty or fee.