The monitoring blind spot
The assets you can't monitor
are the ones most likely to fail.
30–40% of critical rotating equipment has no condition monitoring. Not because it's been overlooked. Because the assets sit where sensors can't go — submerged pumps, sealed blowers, hazardous zones, remote sites.
The gap
A gap measured in downtime, fines, and risk
The assets below the monitoring line aren't low-priority. They're critical rotating equipment in environments where conventional sensors can't operate. Here's what that gap costs.
The cost of inaction
The cost isn't just the repair bill
Unplanned downtime
A single pump failure at a remote site costs €50,000+ in emergency repair, lost production, and overtime. Multiply that across a fleet of unmonitored assets, and the annual exposure runs into millions.
Pollution and regulatory fines
A sewage pump failure causes a spill. The fine alone can reach £390,000. Add the remediation cost, the regulatory investigation, and the reputational damage. One event resets years of compliance work.
Safety exposure
Every manual inspection in a confined space, ATEX zone, or submerged environment puts personnel at risk. The safest inspection is the one your team never has to make.
Wasted energy
A pump operating 7% below its best efficiency point wastes thousands in electricity per year. Across hundreds of unmonitored motors, the energy waste is invisible until someone measures it.
The shift
Move the sensor to the cabinet. Monitor the entire drivetrain.
ESA reads the motor's electrical signature at the MCC. AI detects faults across the full drivetrain — motor, coupling, gearbox, and driven load — weeks to months before failure. No sensors on the asset.
See how ESA works →- Sensor on the asset
- Physical access required
- Production shutdown to install
- Limited in harsh environments
- Sensor at the cabinet
- No asset access needed
- Install in under 30 minutes
- Works everywhere
“We invested heavily in condition-based maintenance — vibration, oil analysis, airflow, the lot. But those approaches can still be snapshots. SAM4 added continuous visibility, and that changes how confident you feel about what's happening.”
Quantify your coverage gap
An asset audit maps your unmonitored fleet, prioritises your highest-risk assets, and gives you the data for an internal business case. No commitment beyond the conversation.