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ELLENEX INDUSTRIAL ASSET MONITORING SOLUTIONS

Low-Power Industrial Telemetry Engineered for Distributed Assets, Extreme Environments, and Zero Downtime

WE OFFER THE WIDEST RANGE OF LOW POWER (BATTERY OPERATED) INDUSTRIAL IOT SOLUTIONS

With more than 25 years of experience in developing industrial solutions, we are proud of offering the most extensive industrial IoT solutions to address the requirements of industries with a high value distributed network of assets. 

With a focus on pressure, level, and temperature measurement, we offer the most advanced "Application Centric Solutions " to reduce the cost and simplify the process for:

  • Predictive maintenance

  • Asset management

  • supply management

  • Service management

  • Workflow management

  • and event prediction

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Infrastructure Intelligence for Mission-Critical Global Industries

Industrial operations depend on capital-intensive assets operating in remote, harsh, and hard-to-access locations. Ellenex delivers carrier-certified, battery-operated sensing architectures and cloud data systems that transform static, unmonitored infrastructure into intelligent, self-reporting networks. By eliminating the heavy capital costs and physical vulnerabilities of conventional field wiring and power cabling, Ellenex enables deep operational visibility across underground municipal vaults, remote wellheads, deep open-pit mines, commercial air-handling systems, and agricultural water networks.

Through multi-bearer connectivity—encompassing LoRaWAN, cellular NB-IoT/LTE-M,—operators capture near real-time telemetry, protect capital assets, ensure environmental compliance, and eliminate catastrophic unplanned downtime.

Operational assets present distinct physical, RF, and mechanical challenges across different sectors. Subterranean mining shafts and dense steel processing plants require decentralized mesh routing to navigate radio frequency obstructions. In contrast, long-distance pipelines and municipal distribution networks rely on licensed cellular penetration. The following matrix details the target environments, measurement parameters, primary instrumentation, and validated operational outcomes for each vertical.

 

Water and Wastewater

Municipal water networks face significant physical losses through hidden pipeline bursts, joint failures, and structural fatigue, frequently losing over 30% of total treated volume to non-revenue water (NRW). Concurrently, industrial wastewater plants and municipal treatment works operate under strict regulatory standards; in the United States, unmonitored effluent violations under the Clean Water Act can trigger non-compliance fines ranging from $25,000 to $50,000 per day. Traditional grab sampling introduces large data gaps that fail to capture sudden contamination events or damaging pressure transients, leaving distribution networks vulnerable to structural failures.

The Ellenex water infrastructure framework digitizes water supply lines and sewer systems using non-invasive, retrofit-ready sensor nodes. By establishing monitored District Metered Areas (DMAs), utilities utilize high-frequency sampling industrial pressure transmitters (PTS2 and PTS3 series) to detect hydraulic transients, water-hammer events, and sudden pressure drops that signal pipeline bursts.

In sewer systems, non-contact DRC3 radar level sensors and PLS3 submersible hydrostatic sensors operate continuously within corrosive hydrogen sulfide manhole environments, alerting control centers to surcharge events and preventing sanitary sewer overflows.

At industrial discharge points, water quality sensors track pH, electrical conductivity/salinity, dissolved oxygen, and turbidity in near real-time, automating compliance reporting and ensuring safe discharge into downstream ecosystems.

The operational applications and measured parameters within this vertical cover:

  • Water distribution pipeline network pressure profiling across DMAs using low-power LoRaWAN (PTS2-L) and cellular NB-IoT (PTS2-N) transmitters.

  • Underground wastewater manhole surcharge, retention wet well depth, and urban stormwater canal tracking via radar and hydrostatic level nodes.

  • Lift station pump operation, cycle timing, and closed-loop motor overload prevention.

  • Continuous industrial effluent quality monitoring, including inline tracking of pH, total dissolved solids, dissolved oxygen, and turbidity.

  • Retrofit integration for mechanical and electromagnetic water meters utilizing low-power digital pulse totalizers (FMS2 series).

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Heavy Industries

Heavy industrial facilities—such as chemical refineries, basic oxygen metallurgy plants, rotary cement kilns, and paper mills—operate critical machinery that manages high thermal, kinetic, and fluid pressures. Unscheduled mechanical outages cost the world's 500 largest industrial organizations an estimated $1.4 trillion annually, representing roughly 11% of total enterprise revenue. Over 40% of these catastrophic interruptions originate from mechanical breakdowns in pumps, industrial bearings, and pressurized process lines. Traditional calendar-based maintenance often leads to unnecessary servicing, while reactive "run-to-failure" repairs can cost three to five times more due to emergency labor, expedited parts delivery, and secondary equipment damage.

Ellenex shifts heavy industrial maintenance from reactive interventions to predictive maintenance (PdM), helping industrial plants reduce overall downtime by 30% to 50% and lower recurring maintenance budgets by 18% to 25%. High-specification industrial pressure transmitters (PTS3 series) measure media pressures up to 1,000 bar across abrasive slurry loops, catalytic cracking columns, and hydraulic presses.

Dual-parameter pressure-and-temperature sensors (PTD2 series) monitor forced-lubrication circuits, detecting hydrodynamic breakdown, oil degradation, and bearing housing thermal runaway well before mechanical failure occurs.

Concurrently, differential pressure nodes (PDS2 series) monitor industrial HVAC, baghouse dust filters, and intake compressors, alerting teams to filter loading to preserve fan efficiency and reduce plant energy use.

The operational applications and measured parameters within this vertical cover:

  • High-pressure static containment monitoring on cracking towers, autoclaves, and high-temperature steam lines.

  • Forced-circulation bearing lubrication line health tracking via dual pressure-temperature (PTD2) sensor arrays.

  • Air compressor and pneumatic distribution performance monitoring, identifying pressure decay and distribution leaks.

  • Tank farm inventory and chemical containment surveillance across diesel, process lubricants, and corrosive chemical reagents.

  • Impressed-current and sacrificial cathodic protection monitoring, validating protective voltages on buried metallic pipelines and tanks.

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Frequently Asked Questions

How can water utilities detect underground pipeline bursts and reduce non-revenue water (NRW)?

Water utilities divide networks into District Metered Areas (DMAs) and deploy high-frequency sampling industrial pressure transmitters, such as the Ellenex PTS2 Series (PTS2-N for cellular NB-IoT/Cat-M1 and PTS2-L for LoRaWAN) and heavy-duty PTS3 transmitters. These battery-powered sensors continuously measure static line pressure and transient pressure spikes (water hammer). By establishing baseline pressure profiles and streaming near real-time data to central SCADA or cloud dashboards, the system identifies sudden pressure drops that indicate pipeline ruptures, helping operators locate leaks rapidly and curb non-revenue water losses that frequently exceed 30% of total treated volume.

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What is the most reliable way to monitor sewer manhole surcharges and stormwater flood levels?

Monitoring subterranean sewer and stormwater chambers requires non-contact or chemical-resistant instrumentation that can withstand high humidity and corrosive hydrogen sulfide gas. Ellenex addresses this with IP68-rated non-contact microwave radar level sensors (DRC3 series) and submersible hydrostatic level sensors (PLS3 series). Installed under manhole covers or beneath bridge decks, these nodes communicate via cellular NB-IoT or LoRaWAN, transmitting level data through cast-iron lids and deep concrete chimneys without external power supplies to provide early warnings for sewer blockages and urban inundation.

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How can operators monitor machinery and assets in underground mines where radio signals cannot penetrate?

Traditional point-to-point wireless signals struggle inside deep shafts, tunnels, and reinforced concrete structures. Ellenex solves underground connectivity challenges by integrating Wirepas decentralized mesh technology into its industrial sensors. In a Wirepas deployment, each battery-powered sensor acts as an autonomous relay node, forming a self-healing mesh that routes hydraulic line pressures, ambient environmental conditions, and structural displacement data around physical obstructions without requiring line-of-sight cabling or high-maintenance repeater stations.

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How does predictive maintenance in heavy manufacturing prevent catastrophic bearing and pump failures?

Unscheduled equipment downtime often stems from mechanical degradation in bearings, gearboxes, and pressurized lubrication lines. Ellenex provides continuous condition monitoring using dual-parameter pressure and temperature transmitters (PTD2 series) alongside high-range pressure transmitters (PTS3 series, rated up to 1,000 bar). Installed directly into forced-lubrication circuits, slurry lines, and hydraulic loops, these sensors detect thermal runaway, fluid viscosity breakdown, and pump cavitation well before catastrophic mechanical seizure occurs, reducing unscheduled outages by 30% to 50%.

 

How can commercial buildings and hospitals ensure HVAC filter efficiency and isolation room pressurization?

Maintaining correct air pressure differentials is vital for indoor air quality, cleanrooms, and airborne infection isolation rooms. The Ellenex PDT2 and PDS2 wireless differential pressure sensors provide continuous, high-precision measurement across Air Handling Unit (AHU) filter banks and room boundaries. Operating over LoRaWAN or NB-IoT, these low-power devices alert building management systems (BMS) when filters become clogged, preventing fan motor burnouts, optimizing air balance, and maintaining audit-ready regulatory records for positive- or negative-pressure biocontainment.

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Can legacy mechanical water meters and analog 4–20 mA sensors be converted to wireless IoT?

Yes. Industrial plants do not need to replace operational mechanical totalizers or analog transducers to achieve cloud connectivity. The Ellenex RS1 Multi-Channel Sensor Interface and FMS2 series pulse interfaces act as universal bridges. The RS1 accepts standard 4–20 mA, 0–5 V, pulse totalizer, and RS485 Modbus inputs, converting readings into encrypted LoRaWAN or NB-IoT payloads that transmit directly to enterprise software, extending the operational life of existing capital equipment.

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How do connected sensors optimize broadacre irrigation and protect livestock water supplies?

Agricultural operations face high pumping energy costs and the risk of herd dehydration during drought. Ellenex provides an integrated agricultural suite featuring multi-depth capacitive soil moisture probes, pipeline pressure transmitters, and submersible tank/trough level transmitters. Soil probes track volumetric moisture across root zones to guide precision irrigation schedules, line-pressure nodes detect ruptured drip lines or clogged nozzles, and water trough monitors deliver automated alerts over LoRaWAN or NB-IoT if tank levels drop, helping reduce livestock mortality.​

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What IoT solutions protect temperature-sensitive cargo and prevent liquid tanker theft during transit?

Intermodal cold chains and mobile liquid haulage require continuous environmental tracking. Ellenex logistics solutions combine multi-channel temperature loggers, hydrostatic level sensors, and low-power GPS/GNSS modules on cellular NB-IoT/LTE-M networks. In refrigerated trailers, temperature nodes stream continuous thermal logs to ensure food and pharmaceutical safety compliance. On bulk chemical and diesel trailers, level sensors track fluid inventory in transit—compensating for slosh—to detect unauthorized discharge and optimize delivery dispatching.

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How does Ellenex handle wireless sensor recalibration and integration with third-party software?

Ellenex simplifies sensor lifecycle management through cloud-based over-the-air (OTA) calibration and a fully documented OpenAPI architecture. Rather than pulling submerged or elevated sensors from the field for manual re-zeroing, technicians can adjust zero-point offsets, span values, and linearization factors remotely via the Ellenex cloud interface. All calibration updates generate cryptographically timestamped audit logs, while RESTful APIs allow telemetry to feed directly into SCADA, enterprise ERP, and Building Management Systems.

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Cities and Councils

Municipal councils and urban authorities manage large, distributed infrastructure networks that encompass roadways, stormwater drainage culverts, fire prevention water networks, and public utilities. As extreme weather events grow in frequency, urban storm channels and subterranean drainage systems face rapid hydraulic overloading, resulting in street-level flooding, roadway subsidence, and property damage. Concurrently, local governments must optimize public service delivery—including solid waste collection, public landscape irrigation, and structural safety management—while working within constrained municipal operating budgets.

Ellenex delivers low-power sensor networks that provide municipal engineers and emergency operations centers with continuous operational visibility. Non-contact microwave radar devices and submersible hydrostatic level sensors deployed inside stormwater culverts, retention basins, and river crossings detect rapid water rise, automatically triggering flood diversion gates, municipal warning systems, and road closure protocols.

The operational applications and measured parameters within this vertical cover:

  • Subsurface stormwater culvert, urban canal, and river level monitoring for automated flood hazard warnings.

  • Municipal sewer surcharge and underground overflow tracking via low-power radar and hydrostatic sensors.

  • Dedicated municipal firefighting water supply loop and hydrant distribution pressure verification.

  • Civil structural stability tracking, including land-slip detection, pavement load stress, and guardrail cable tension.

  • Smart city service automation, covering public park smart irrigation and solid waste bin fill-level tracking.

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HVAC and Buildings

Heating, ventilation, and air conditioning (HVAC) systems represent the single largest operating energy expenditure in commercial real estate, data centers, and institutional facilities. In large Air Handling Units (AHUs), air filters gradually load with particulate matter; without continuous differential pressure tracking, fans draw higher electrical current to overcome media resistance, causing premature fan motor burnout and driving building energy costs up. In sensitive environments—such as hospital airborne infection isolation rooms (AIIR), cleanrooms, and pharmaceutical labs—improper differential pressure can cause biological containment leaks or particulate infiltration, compromising sterile protocols.

The Ellenex HVAC and smart building platform modernizes building automation by replacing mechanical gauges and wired transmitters with ultra-low-power differential pressure sensors (PDT2 and PDS2 series). Capable of resolving minute pressure differentials down to fractions of a Pascal, these devices transmit real-time data across central AHU filter banks, enabling condition-based filter maintenance that optimizes replacement intervals and preserves fan motor life.

The operational applications and measured parameters within this vertical cover:

  • Air Handling Unit (AHU) filter pressure differential monitoring for condition-based filter change-out schedules.

  • Critical space pressure management, including positive pressure in cleanrooms and negative pressure in healthcare isolation wards.

  • Static duct air pressure and velocity inference across variable air volume (VAV) distribution systems.

  • Emergency backup power fuel security, tracking underground and day-tank diesel levels.

  • Building water supply integrity, domestic hot water distribution temperatures, and localized leak detection.

Agriculture and Farming

Agricultural operations consume roughly 70% of global freshwater withdrawals. Faced with recurring droughts, soil salinity accumulation, and rising energy costs for deep groundwater pumping, modern producers require precise hydrological data to sustain operations. In animal husbandry, unpredicted failures in remote water troughs during extreme heat can lead to rapid herd dehydration; during the 2017–2019 Australian drought, water scarcity contributed to an estimated 18% decline in national sheep and cattle herds. In broadacre cropping, uneven distribution pressures across center-pivot and drip lines cause uneven watering, wasted fertilizer, and excess pumping energy.

Ellenex agricultural solutions help farming enterprises optimize the water-energy nexus across crops and livestock. Multi-depth capacitive soil probes continuously map volumetric soil water content, temperature, and electrical conductivity through the root zone, enabling growers to schedule irrigation based on crop evapotranspiration rather than arbitrary timers. Field deployments demonstrate that data-guided irrigation can increase crop yields by up to 60% while reducing water usage by over 15%.

The operational applications and measured parameters within this vertical cover:

  • Multi-depth root-zone soil moisture, temperature, and electrical conductivity profiling for precision irrigation management.

  • Irrigation mainline and drip distribution manifold pressure consistency and burst pipe monitoring.

  • Remote livestock pasture drinking trough, holding tank, and pastoral dam volume telemetry.

  • Deep extraction aquifer groundwater table depth and agricultural bore drawdown analysis.

  • Bulk storage inventory tracking for on-farm diesel reserves, liquid fertilizers, and grain silos.

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Logistics and Delivery

Intermodal transport, bulk liquid freight, and temperature-controlled logistics depend on uninterrupted visibility across long distribution routes. For refrigerated goods—such as biologics, vaccines, and perishable foodstuffs—unnoticed failures in transport refrigeration units (TRUs) lead to total load losses and regulatory violations under international food and drug safety standards. In bulk liquid transport, tracking contents within moving ISO tanks, fuel tankers, and chemical trailers often relies on manual estimation, leading to route inefficiencies and unauthorized off-loading. Furthermore, improper cargo weight distribution leads to structural chassis fatigue and highway axle-weight violations.

Ellenex logistics systems pair low-power sensing hardware with cellular LPWAN connectivity and integrated low-power GNSS location tracking. Multi-channel temperature loggers transmit cargo thermal profiles from inside refrigerated reefers, providing an unbroken, audit-ready temperature log. The platform alerts dispatchers the moment cargo temperatures drift toward critical thresholds, allowing drivers to address refrigeration faults before product degradation occurs.

The operational applications and measured parameters within this vertical cover:

  • Refrigerated shipping container, truck reefer, and static cold-room temperature loggers for pharmaceutical and food safety.

  • Mobile ISO tank, fuel tanker, and chemical delivery trailer fluid volume tracking with dynamic slosh compensation.

  • Heavy transport vehicle onboard axle mass calculation to prevent structural damage and highway overloading.

  • Haulage fleet hydraulic line pressures, pneumatic brake system operation, and compressor health.

  • Distributed industrial gas cylinder storage, manifold distribution, and mobile liquid nitrogen/carbon dioxide levels.

Oil, Gas, and Energy

Ellenex addresses upstream and midstream operating risks with intrinsically safe (IECEx-certified) instrumentation built specifically for explosive environments. By integrating direct-to-satellite connectivity alongside NB-IoT and LoRaWAN, Ellenex sensors operate autonomously in remote fields, transmitting pipeline pressure, separator status, and wellhead dynamics directly into central SCADA systems.Upstream wellheads, midstream pipeline networks, and downstream tank farms operate under challenging operating conditions marked by explosive atmospheric hazards, remote geography, and corrosive fluid chemistry. Production gathering lines and storage facilities are frequently located in isolated areas lacking reliable cellular coverage or utility power, forcing operators to rely on manual inspections that expose personnel to hazardous volatile hydrocarbons and hydrogen sulfide. Furthermore, undetected pressure surges or internal structural corrosion across long-distance pipelines present major risks of containment loss, fires, and costly environmental remediation.

The operational applications and measured parameters within this vertical cover:

  • Long-distance pipeline pressure monitoring, burst identification, and water-hammer surge detection.

  • Storage vessel level management for crude oil, natural gas liquids, condensate, and pressurized LPG tanks.

  • Wellhead casing, tubing, and manifold pressure tracking in remote upstream extraction fields.

  • Cathodic protection monitoring, logging pipe-to-soil potentials to prevent electrochemical pipeline corrosion.

  • Electrical utility substation health monitoring, tracking transformer insulating oil levels and temperatures.

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Mining and Construction

Open-pit extractions, underground mine developments, and civil infrastructure construction operate under severe mechanical shock, high dust loads, and dense subterranean RF interference. Unscheduled downtime on primary processing machinery—such as semi-autogenous grinding (SAG) mills, mobile drilling rigs, and high-volume conveyors—generates losses reaching $180,000 per hour. At the same time, managing geotechnical safety across Tailings Storage Facilities (TSFs), heap leach pads, and retaining cuts requires continuous surveillance of pore water pressure and slope stability to prevent catastrophic structural collapses that endanger human life and cause long-term environmental damage.

Ellenex provides ruggedized, IP68-rated monitoring nodes built specifically for severe industrial environments. For enclosed primary crushers and feed hoppers where abrasive rock dust abrades contact instruments, non-contact FMCW radar sensors track ore levels with high precision.

The operational applications and measured parameters within this vertical cover:

  • Tailings Storage Facility (TSF) decant well levels, pond freeboard elevations, and dam crest clearances via non-contact FMCW radar and submersible hydrostatic transmitters.

  • Heavy machinery health monitoring, tracking hydraulic pressures, pneumatic supply feeds, and conveyor bearing temperatures to isolate cavitation and mechanical wear.

  • Subsurface mine safety tracking, providing near real-time telemetry on air shaft static pressures, ambient humidity, and toxic environmental conditions.

  • Geotechnical civil engineering assessments, monitoring borehole pore pressures, structural retainment strain, and ground shifting.

  • Mining fleet logistics control, managing diesel storage reserves, dynamic truck onboard axle loading, and mobile reagent deliveries.

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