CaseiZ

Compressed air systems are among the most energy-intensive utilities in manufacturing, accounting for 10% to 50% of a plant's total energy consumption depending on the industry — yet they are routinely overlooked. In most facilities, compressors are installed individually in utility rooms, running on local control without integration into the broader automation network. This isolation makes inefficiencies nearly invisible until an energy audit reveals the true cost. CaseiZ, a specialist in compressed air, vacuum, and cooling water optimization, found that many customers operated compressors more than 30 years old, with no real-time visibility into performance. The result: significant, sustained energy waste with no mechanism to detect or correct it promptly.

CaseiZ developed AirView Cloud, a cloud-based monitoring and optimization platform built on PTC's ThingWorx IIoT platform — part of Rockwell Automation's FactoryTalk InnovationSuite. Engagements begin with a week-long on-site energy savings audit, during which data loggers establish performance baselines and identify inefficiencies. CaseiZ then modernizes obsolete compressor systems using Allen-Bradley CompactLogix or ControlLogix controllers with FactoryTalk View HMI, integrated over EtherNet/IP networks. AirView Cloud connects these upgraded systems to the ThingWorx platform, enabling real-time monitoring of runtime patterns, machine utilization, and key performance indicators across individual compressors. Automated alerts notify both the customer and CaseiZ teams when a compressor trips offline or a KPI drops below threshold, replacing a labor-intensive monthly manual report with continuous, actionable visibility.

CaseiZ consistently uncovers energy savings of 25% to 50% per engagement — primarily driven by automation platform upgrades and system integration. Before AirView Cloud, performance tracking relied on manual monthly snapshots that required engineers to remotely log into local control panels and generate reports by hand. Real-time visibility eliminated that lag:

• 25–50% energy savings achieved through compressor optimization and system integration
• Monthly manual reporting replaced with continuous real-time monitoring and automated alerting
• Rapid issue resolution: efficiency drops from compressor failures or unexpected adjustments are now detected instantly
• AirView Cloud expanded to more than a dozen diverse customer sites within less than one year of initial deployment
• First automotive customer converted from the included first-year service to a paid subscription upon eligibility

• Compressors running on isolated local control — not integrated into plant-wide automation — are among the most common and correctable sources of energy waste in manufacturing facilities.
• A structured baseline audit (data loggers, one week on-site) is essential before recommending any optimization solution; without it, potential savings remain invisible.
• Moving from periodic static reports to real-time IIoT monitoring shifts the team's effort from data collection to problem resolution — a force multiplier for support efficiency.
• Offering the monitoring platform bundled with turnkey projects for the first year reduces adoption friction and lets customers validate ROI before committing to a subscription.