Dynamic Air

Dynamic Air, a global leader in dense phase pneumatic conveying systems with more than 15,000 installations worldwide, faced a core operational challenge: customers had no reliable way to monitor Overall Equipment Effectiveness (OEE) in real time. OEE requires aggregating quality, performance, and availability data from disparate systems — a calculation that was difficult to obtain accurately and continuously. Without real-time OEE visibility, plant managers could not quickly identify inefficiencies, minimize waste, or respond to equipment issues before they escalated. COVID-19 further complicated the ability to deliver on-site service, exposing the need for a remote, data-driven service model.

Dynamic Air developed TED-D (Technology Embedded Data – Dynamic Air), a proprietary IIoT solution built on the ThingWorx IIoT Platform from Rockwell Automation and PTC. The platform aggregates data from PLCs, edge devices, servers, and the cloud to deliver real-time OEE dashboards to operators and plant managers. Delivered as a monthly subscription service, TED-D establishes an ongoing remote connection with each customer installation. The system enables Automation Engineering teams to remotely execute performance evaluations, run parameter verifications, collect startup data automatically, and access program logic virtually. Rockwell Automation, already an established partner, was selected after nearly two years of vendor evaluation based on data security standards, digital transformation expertise, and a roadmap that included future capabilities such as predictive ML and augmented reality.

TED-D demonstrably strengthened Dynamic Air's competitive position in the market. The solution directly contributed to winning a new order for a pneumatic conveying system — with the customer citing TED-D's digital capabilities as a differentiating factor. Qualitative outcomes included:

• Remote service delivery enabled Dynamic Air to maintain service quality standards during COVID-19 restrictions without on-site visits
• After-Sales and Spare Parts teams gained predictive visibility into upcoming service and parts needs, improving planning cycles
• Plant operators gained continuous, contextualized OEE data previously unavailable from siloed systems
• The subscription model created a recurring revenue stream and strengthened long-term customer relationships

• Two years of vendor evaluation paid off: Dynamic Air's disciplined selection process — prioritizing data security, digital transformation experience, and future-proof architecture — produced a platform they could build on incrementally.
• Package remote access into the product: Embedding remote monitoring as a subscription service, rather than a one-time feature, turns an IIoT investment into a recurring revenue model.
• OEE is a high-value entry point: Real-time OEE resonates with plant managers because it aggregates metrics they already track — making adoption easier than introducing entirely new KPIs.
• Design for extensibility: Building TED-D on a platform with a roadmap for ML and AR ensures the investment remains relevant as Industry 4.0 capabilities mature.