Industrial IoT Solutions for Factories, Plants & Utilities

Industrial IoT is IoT applied to plants and factories. The idea is the same, connected devices sending data to software, but the equipment is built for a harder job: sealed enclosures, wide temperature ratings, long battery life, and industrial interfaces such as RS485 Modbus and 4–20 mA so it can read the meters, PLCs and instruments already on site.

They are related, not the same. Industry 4.0 is the idea of a plant whose machines, utilities and stores report their own condition, and a smart factory is a plant that has got there. Industrial IoT is the means: the sensors, converters and networks that collect the data. Most plants start smaller than the phrase suggests, by connecting the equipment they already have and getting one reliable set of readings.

Yes, and this is how most plants start. If the equipment has an RS485 Modbus port or a 4–20 mA or 0–10 V output, a MacSync converter reads it and sends the values over LoRaWAN, Wi-Fi or 4G. The machine, its controller and its wiring stay as they are. Where there is no usable output, a wireless sensor is added beside the equipment instead.

Usually neither. A converter is wired to a spare RS485 port or in parallel with an existing 4–20 mA signal and only reads, so the PLC program is not touched. Non-contact and surface-mounted sensors go in while the process runs. A sensor that sits inside a tank or a pipeline is the exception and is normally fitted at a planned stop.

It depends on distance and data. LoRaWAN suits many battery-powered points spread over a large site, because one gateway covers a plant and there is no per-device fee. Wi-Fi suits indoor points inside reliable coverage that need to send more data, more often. 4G suits a single remote asset with no local network. Most plants use more than one, and Macnman builds the same converters and controllers for all three.

An outdoor MacLink Gen 2 gateway typically covers 2 to 5 km in built-up areas, and an indoor Setu X1 gateway 1 to 2 km. Steel structures, basements and thick walls reduce that, which is why a coverage check comes before an order. Each gateway has eight channels and supports more than 2,000 devices, so capacity is rarely the limit in a single plant.

LoRaWAN sensors and converters run for years on a 19 Ah lithium cell, up to 10 years at long reporting intervals. Wi-Fi costs more energy per message: the MacSync WX1 converter is estimated at about 2.5 years on 15-minute uploads and 6.7 years on hourly uploads. The battery life calculators on this site estimate the figure for your own interval, and DC-powered variants are available where a supply exists.

No. A LoRaWAN network server and an MQTT broker can both run on a machine inside the plant, so the data never has to leave the site. Macnman devices do not require a subscription to work. A cloud platform is an option for multi-site visibility, not a condition of using the hardware.

Yes. The devices deliver data over open protocols: LoRaWAN to any standard network server, and MQTT or HTTPS from the Wi-Fi and 4G devices. Most SCADA, MES and analytics platforms accept one of these directly or through their own connector. Send us the name of the platform and we will confirm the route.

For monitoring and supervisory control, yes. Readings are sent on a schedule, converters store data on board and forward it after an outage, and controllers run their rules locally. Wireless should not carry safety interlocks, emergency shutdown or fast closed-loop control. Those stay wired.

Yes, if each machine or feeder has a Modbus energy meter, which most panels already do or can have added. A MacSync converter polls the meters on one RS485 line and reports kWh, demand, voltage, current and power factor per meter. That shows which line, shift or machine uses the energy, which a single incomer meter cannot.

Yes. A LoRaWAN capacitive fuel level sensor in the day tank or bulk tank reports the diesel level continuously to ±1% of full scale. Refills, consumption and sudden drops all show in the trend, and a low-level alert can be raised before the tank runs dry. Generator controllers with a Modbus port can also be read through a MacSync converter.

Temperature-based condition monitoring is covered directly: PT100 probes through the RTD sensor, and non-contact infrared for hot or moving surfaces. For vibration, a transmitter with a Modbus or 4–20 mA output connects through a MacSync converter and its values travel over the same network. Tell us the machines and we will suggest the measurement points.

The standard devices are industrial, IP65 with an IP67 option, and are not certified for use in hazardous (Ex) zones. Tell us the zone classification before ordering and we will confirm what can be used and where it can be mounted.

IN865 for India and EU868 for Europe, plus US915, AU915 and RU864, with KR920 and AS923 on selected products. The band is fixed by the country's regulations, so tell us where the devices will be installed and we supply the matching variant.

Yes. As the manufacturer, Macnman adapts firmware, payload formats, enclosures and branding for OEM and project orders. Customisation depends on volume, so share the quantity and the change you need and we will tell you what is possible.

Yes. Macnman Technologies designs and manufactures its sensors, converters, controllers and gateways in Pune, Maharashtra, and supports them directly from the engineering team.

Yes. LoRaWAN devices are built in regional band variants: IN865 for India, EU868 for Europe and the countries that follow the European plan, plus US915, AU915 and RU864. The Wi-Fi and 4G devices do not depend on a LoRaWAN band. Tell us the country of installation and we will confirm the band and the variant to order.

With one problem and a few devices. Pick a single job, such as sub-metering one feeder or watching one fuel tank, and tell us the signal type, the distance and the reporting interval. We specify the devices and the gateway, you confirm the data reaches your platform, and the same network then takes on more points.