Continuous compressor load drawn by a single 3 mm leak at 6 bar. Most plants carry 10–30 active leak points.
Annual cost of that single leak at 2026/27 SA Mega Flex tariffs. Multiply by the leak count.
Payback on a ~R 40k smart flow sensor that finds the leak. Every leak after that is profit.
Math · US DOE / Compressed Air Challenge · 3 mm orifice at 6 bar ≈ 5 kW · 5 kW × 8,760 h ≈ 43,800 kWh/yr · at ~R 1.80/kWh effective marginal cost on Mega Flex 2026/27 (incl. legacy + ancillary + affordability charges, excl. VAT) ≈ R 80k
Each item is smart in the engineering sense – embedded electronics, IO-Link or wireless backhaul, native UVIX integration. Buy one for a single line, scale to a plant later.
Modular pneumatic valve island. Each coil reports current draw, response time, switching count, and temperature – flagging worn coils, sticking spools, and hot-running solenoids before they fail.
Closed-loop pressure control in software. Sets, reads, and reports actual line pressure live. Replaces mechanical regulators where setpoints need to change per recipe or batch.
Compressed-air flow and dewpoint measurement on the same instrument. Quantify what your air dryer actually does – and prove it on a continuous record, not a once-a-year audit.
Browser-based dashboard, native mobile views, configurable alerts. The same platform Camozzi customers in Italy and Germany use – accessible to your maintenance team on a phone.
You do not need to gut your plant to go smart. The four building blocks each work standalone – and stack into a complete asset-monitoring system as you go.
Drop-in a Series D island and an FSX flow sensor on a problematic line. Connect to UVIX in an afternoon. See data the next shift.
Where you have variable-pressure recipes or batch changeovers, drop in a Series PRE. Setpoints follow the SCADA without retrofitting field instruments.
Once the first line proves out, the playbook is repeatable. UVIX rolls up – line, area, plant – without re-architecting.
Smart pneumatics are not equally valuable everywhere. These are the four South African industries where the maths consistently works.
Compressor-air audits routinely find 25–40% loss to leaks and mis-set regulators. UVIX makes that loss visible and fixable.
High-cycle valves are the #1 unplanned-downtime cause. CoilVision flags a failing coil's degradation trend before it sticks.
Dewpoint excursions are a HACCP risk. FSX gives you the continuous proof-of-air-quality record auditors actually want.
Recipe-driven pressure control + traceable sensor data = qualification-grade air. Series PRE + UVIX is purpose-built for this.
We'll open the same dashboard real plants run. 20 minutes, browser tab, no commitment.
