June 11, 2021

IoT Condition Monitoring – Comparing Alternatives

IoT has proven itself to provide unique value in commercial or industrial applications, even in the presence of the sensors and control systems that are already installed.

IoT has proven itself to provide unique value in commercial or industrial applications, even in the presence of the sensors and control systems that are already installed.  The reason; IoT has found a niche for itself in being able to easily supply trend data for virtually any kind of sensor, whether already installed or newly installed for the benefit of IoT. This trend data is the basis of more advanced capabilities like predictive maintenance. Looking at these control alternatives, you typically have control systems (PLC’s) or commercial controllers (distributed controllers, building management systems, etc) also installed in the same facility, now also starting to offer IoT like capabilities.

But – what exactly are the technical and cost differences?  This is an important consideration when trying to decide on a long term IoT strategy. The table below breaks it down:

AreaIoT Condition MonitoringIndustrial ControllersCommercial Controllers
Application FocusTrending sensor dataMachine ControlProcess Control
Application ValuePredictive Maintenance(Re) ProgrammabilityAutomated process mgmt
Underlying architectureInternet basedProprietaryProprietary 
Comms BackboneCellular / WiFiProprietary EthernetProprietary + Ethernet
InstallationOff GridNeeds Plant Network Needs Plant Network
Personal User I/FSmart Phone AppsNoneNone
Supervisory User I/FCloud (Web)OptionalProprietary
Cost to add (1) sensorFreeAverage $800Average > $1500
ExtensibilityNone – Fit for PurposeUser extensibilityExtensible w/ factory help
Target UserMaintenance TeamsFacility EngineersPlant Engineers / Mgrs

The red highlight is, in our opinion, the main differentiator of the three solutions.  It is pretty clear that the three were designed for different things.  But as control companies begin to offer IoT capabilities, users will need to decide which approach to take, as the benefits of IoT have become compelling. 

Industrial controllers are priced by how much I/O and memory (rated in kilobytes or megabytes) it supports, whereas this is not even a factor in the IoT world. In commercial controllers, systems are most often turnkey installations from one of the big commercial control companies, and pricing is usually turnkey based on the size of the contract. Other than IoT, the primary objective is one thing and one thing only: control. Either machine control or process control, with the new concepts of IoT being an afterthought, not designed in from the beginning 

With IoT, the application comes out of the box, more like a SaaS (software as a service) application, preprogrammed and ready to use on day one. This is great for maintenance teams. It is designed to be ‘off grid’ – no plant network integration required.  So once sensor data is available, it can be trended, then fed into machine learning and other advanced algorithms, only then can it provide the one thing that alternatives are trying to provide: predictive maintenance.  Can control systems store sensor data, trend it, apply machine learning, and visualize it on a web screen? Yes, absolutely.  It’s just a lot of work, a lot of programming, a ton of integration, and finally you may end up with something not very usable by the target user- maintenance teams.  Today, what we mostly see are independent systems, and that makes the IoT system a check for the control system.  Most plants today are working through integration scenarios using CMMS systems, so they get the best of both.  

The bottom line – in IoT based condition monitoring applications – Simplicity counts.  Easier to use and easier to understand means adoption, which leads to a better ability to predict equipment issues, and finally reduce downtime. Want to learn more?  Contact us at


About us

Based in the greater Boston area, the team at Preddio Technologies™ combines decades of experience in industrial and commercial IoT applications.

After launching a widely successful sensor, cloud platform, and mobile application while working in partnership with A.W. Chesterton Company, the team realized the opportunity for similar IoT solutions across the industrial and commercial markets.

Want to learn more?

Preddio Simplicity is super easy to install, but if you need a hand just give us a call. We have experience freeing captive data from all types of industrial systems and enjoy helping customers develop breakthrough solutions.

Download our whitepaper

Contact us