Condition
Monitoring
Remote Monitoring & Early Warning Systems
Predictive Reliability for Critical Assets
Current Installations
Aggregates
Quarries, crushers, conveyors & screening equipment
Feed Mills
Grain processing, pellet mills & material handling
Asphalt
Hot mix plants, drum dryers & batch mixing systems
Food Production
Processing lines, mixers, chillers & packaging
Remote Monitoring
Traffic Light Monitoring — Across Your Entire Plant
Connectivity
99.8% UK Coverage
Highly dependable 2G cellular connection on any network. Operating on all providers with non-steered roaming SIMs. External antenna with 5M cable for additional signal strength.
5-28V input voltage compatible.
Key Features
Secure 24/7 monitoring of motors, gearboxes, pumps, fans, bearings & more
Customisable warning thresholds with 90 days of data history
Predictive warnings & early warning monitoring notifications
Fully accessible live updates on any internet-connected device — Phone, Tablet, PC
GEO based mapping of assets allows easy deployment of personnel
Highly dependable 2G cellular on 99.8% UK coverage — non-steered roaming SIMs
Remote Sensing — Errors & Warnings
Monitor Types
External Input
Connect to automatic lubricators, PLCs, and existing sensors. Versatile integration with any industrial control system.
Electric Motor
Three-phase current monitoring, vibration analysis, and temperature tracking. Real-time data via mobile app.
Access from any device
View real-time data on smartphone, tablet, or desktop. QR codes on each unit for instant PM schedule access.
How It Works
Connect
Sensors connect directly to the application, powered via 5-38V. Compatible with existing or new sensors.
Supports vibration (XYZ axis), temperature, current, voltage, and 4-20mA inputs. Wireless RF communication eliminates complex wiring.
Record
Data is recorded at set intervals and transferred to a 90-day rolling memory for comprehensive history.
Configurable sampling from 1 minute to 24 hours. Onboard memory stores 90 days of historical data even during network outages.
Visualise
Data is converted into graphical trends displaying equipment performance & predicted life cycle.
Interactive dashboards show real-time values, historical trends, and comparative analysis. Export reports in PDF or CSV format.
Alert
Major faults trigger push notifications via email. Custom thresholds ensure early warning of problems.
Three-stage traffic light system (Normal/Warning/Fault). Customizable thresholds per sensor. Email, SMS, and push notifications available.
Modular
System is modular — can be added to over time to build a much larger monitoring infrastructure.
Start with critical assets and expand gradually. Each monitor supports up to 11 sensors. Centralized Asset Sentinel Hub manages unlimited monitors.
Simple
Easy install, easy set up, low running costs. Low-cost trial allows proof of concept without major investment.
Magnetic or adhesive mounting. QR codes on each unit for instant mobile access. No specialist training required.
Technical Capabilities
Beyond the core workflow, the Howcroft Sentinel system offers advanced features for comprehensive condition monitoring.
Wireless Communication
Long-range RF transmission up to 100m line-of-sight. Mesh network capability for extended coverage.
IP67 Rated Hardware
Rugged enclosures withstand harsh industrial environments. Operating temperature -20°C to +70°C.
5+ Year Battery Life
Low-power design with user-replaceable batteries. Solar charging option available for remote locations.
Mobile App Integration
iOS and Android apps for on-the-go monitoring. Scan QR codes for instant asset data access.
Predictive Analytics
AI-powered trend analysis predicts failures before they occur. Calculate remaining useful life (RUL).
Energy Monitoring
Track electrical consumption alongside vibration. Identify energy waste and optimize efficiency.
Typical Implementation Timeline
Site survey & critical asset identification
System design & sensor placement planning
Hardware installation & configuration
Staff training & system handover
Monitoring Dashboard
Interactive DemoHistorical Trend Analytics
Multi-sensor overlay · failure correlation detection
Dashed lines = warning / fault thresholds · Toggle sensors above · Drag brush to zoom
Live Alarm Thresholds
Drag handles to adjustAmber handle = Warning threshold · Red handle = Fault threshold · Dot = current live reading
Asset Detail View
Vib Avg
4.7 mm/s
Vib Peak
10.1 mm/s
Temp Avg
59 °C
Temp Peak
69 °C
30-Day Trend
- Vib (mm/s)
- Temp (°C)
Recurring Failure Pattern Detected
2 faults and 2 warnings in history. Multiple faults suggest an underlying root cause — consider a reliability review.
Maintenance History
5 entriesBearing failure — high vibration (12.4 mm/s). Replaced bearing assembly.
Smart Notifications
Custom alerts stored digitally. Set warning and fault thresholds per sensor.
Maintenance Logs
Add device logs, images, text and files for complete maintenance tracking.
Multi-Device Access
Available on all mobile tablets and desktops with Email, SMS & Push notifications.
Historical Graphs
Accurate equipment health trends. Compare sensor data across specific date ranges.
Threshold Config
Simple traffic-light configuration of warning and fault thresholds for each sensor.
Up to 11 Sensors
Add multiple sensors per asset — monitor vibration, temperature, current & more simultaneously.
TCE Monitor
Total Inventory & TCE Monitor: Real-Time Monitoring, Automated Lubrication, 90 Day Rolling Memory, Historical Trend Graphs, Smartphone Geo-Mapping, Traffic Light Warning System.
Scan to Schedule
Quickly access asset details and schedule maintenance via QR code.
Historical Trend Graphs
Visualize long-term performance and identify potential issues early.
Smartphone Geo-Mapping
Locate assets and view their status on the go with mobile mapping.
Traffic Light Warning System
Intuitive visual alerts for immediate understanding of asset health.
Production Board
Board Components
Combined Heat & Vibration Sensors
CT Leads (Electrical Current Sensors)
High Heat Sensors (reconfigurable)
MCU (Main Control Unit)
Technical Diagrams
System Architecture — Sensor Slots & CT Connections
4a. Wiring Diagram — Full Component Layout
Site Specification Required
Installation
Sensor Orientation
Horizontal
Side to side
Axial
In line with sensor cable
Vertical
Perpendicular to sensor cable
Good Practice
Hard fixed sensor to asset using screwthread or self-tapping screw
Adhesive applied to plate on curved surface or adaptor bracket
Hard fixed bracket — then sensor hard fixed to bracket
Soft materials should NOT be used as fixing medium
Real-World Installations
Motor bearing housing — hard-fixed sensor with screwthread mounting
Motor casing installation — secure cable routing to junction box
Industrial gearbox — adhesive plate mounting on curved surface
Things to Avoid
Incorrect installation significantly impacts monitoring accuracy. Follow these guidelines to ensure reliable data.
Units Too Close Together
Communication units placed too close together cause RF interference, degrading signal quality and reliability.
Inaccessible Positions
Placing units too high or too low prevents easy observation of Power & Signal Indicators.
Excessive Adhesive
Using too much adhesive or soft materials as fixing medium causes problems with vibration reading transference.
Soft Mounting Materials
Rubber pads, foam tape, or flexible mounts absorb vibration energy and produce inaccurate sensor data.
Common Installation Mistakes
Communication units placed too close together cause RF interference, degrading signal quality and reliability
Communication units in inaccessible positions (too high or too low) - to ensure Power & Signal Indicator can be observed easily
Cost Savings & Benefits
Prevent failure. Save money.
Reduced Motor Replacement Costs
Component lifetime is increased by early warning of performance issues, avoiding catastrophic failure.
Reduced Downtime
Motors, gearboxes & bearings replaced during planned downtime — not unplanned stoppages.
Lower Electricity Costs
Taking an inefficient motor out of service delivers direct electricity savings and CO₂ reduction.
Extended Equipment Life
Overheating & vibration proven to reduce rotating component lifetime. Average motor life: 30,000 hours.
Insulation Life Protection
Motor insulation life is reduced by 50% when overheating and over-current conditions occur.
Sustainability & Net Zero
Direct contribution to customer sustainability and Net Zero targets through energy efficiency gains.
Want to see your numbers?
Use our interactive calculator to estimate your site's potential savings.
Comprehensive breakdown of cost savings across motor lifecycle, downtime prevention, energy efficiency, and sustainability targets
Case Studies
Explore fault detections, before-and-after data, and the preventative actions that saved these sites significant costs.
Why Howcroft Condition Monitoring?
Use as an Early Warning System
Use as a Reliability Tool
Use for Continuous Improvement Analysis
Works at all levels & easy to understand
Alerts before failure — intervention takes place in time
Ready to protect your critical assets?
Request a free site survey or get a tailored quote — no obligation.
Ready to Eliminate Unplanned Downtime?
Stop guessing. Start monitoring.
Don't wait for a catastrophic failure to tell you your equipment is struggling. With the Howcroft Sentinel early warning system, you gain the 24/7 technical oversight needed to protect your assets, reduce electricity costs, and hit your Net Zero targets.
Low-Cost Entry
Start with a modular trial to prove the concept without major upfront investment.
Rapid Integration
Our "easy install" system works with your existing sensors or can be deployed with our high-precision XYZ vibration and heat sensors.
Total Visibility
Access your equipment's health from any smartphone, laptop, or tablet—anywhere in the world.
Intervention before failure. Reliability by design.
Scan. Sync. Schedule.
Every Howcroft monitor features an external QR code. Simply scan it with your mobile to instantly view the 90-day rolling memory and update your maintenance log on the spot.
Condition
Monitoring
Remote Monitoring & Early Warning Systems
Predictive Reliability for Critical Assets