New tool for predictive maintenance

Augsburg, 3 February 2026 - With isa.guard, Blueserv, the service brand of Hosokawa Alpine, is presenting an innovative tool for predictive maintenance based on over 30 years of experience and the monitoring of more than 1,000 machines worldwide. The aim of the machine and plant engineering company, which specialises in powder processing and blown film systems, is to avoid downtimes, reduce operating costs and extend the service life of systems.

The predictive maintenance tool isa.guard combines continuous sensor data and process monitoring with expert analyses to detect anomalies in real time and proactively plan maintenance interventions. By analysing vibration and process data in real time, isa.guard provides precise machine status diagnostics - at any time and independent of the system. "With monitored systems, we achieved a prediction accuracy of up to 100%," reports Ralph Klaunig, Senior Vice President Blueserv at Hosokawa Alpine.

isa.guard provides customers with a forward-looking service - around the clock. This ensures that the customer systems run without interruption. The machine data is analysed by an international team of around 60 data analysts and engineers. They also draw up customised action plans for customers to prevent damage. Compared to classic condition monitoring, the experts analyse the data and create precise forecasts - often years in advance. Clear reports, recommendations and direct exchange ensure real maintenance reliability. Another advantage that the solution offers is that Blueserv's experts also have in-depth OEM process expertise and can therefore not only evaluate the machine data, but also optimise operating processes on this basis. isa.guard runs independently of the system and does not require access to the company network. "With isa.guard, we ensure maximum system availability, full transparency and sustainable increases in efficiency. Companies can therefore sit back and relax," says Klaunig.

isa.guard is an integral part of isa.io - a modular product family that supports industrial production through real-time data analysis, system connectivity and intelligent automation. isa.io includes several modules, including isa.view for visualising process data and isa.analyse, which identifies ideal conditions and derives specific recommendations for action. As a result, isa.io increases efficiency, transparency and reliability. "isa.io is scalable, cost-efficient and easy to integrate. In short: isa.io transforms complex processes into actionable insights," summarises Klaunig.