Industrial steam systems face failure rates of ten to twenty percent, causing massive energy losses and compromised thermal efficiency. Manual audits are intermittent and fail to capture real-time leaks or blockages across the network, leaving critical assets vulnerable to neglect. Faclon Labs provides wireless, battery-powered sensors for continuous, automated steam trap diagnostics that bridge this visibility gap. By applying advanced failure analytics, we transform a maintenance headache into a streamlined, automated process that detects leaks the moment they occur
Wireless temperature and acoustic data collection across critical steam traps
Continuous failure diagnostics and health tracking without manual inspections
Actionable insights to reduce energy losses and improve steam system reliability
Tangible operational and sustainability gains delivered through continuous steam monitoring
ROI < 12 Months
Recovered investment rapidly through the systematic elimination of steam leakage losses across the entire plant
100% Audit Automation
Replaced manual and third-party steam trap audits with continuous digital monitoring for absolute network visibility
MTTR Reduced by 85%
Enabled faster identification and repair of failed steam traps to minimize energy loss and operational downtime
15% Reduced Carbon Footprint
Lowered steam wastage, directly reducing fuel consumption and associated carbon emissions for sustainability goals
Solution Highlights
Core system capabilities designed for reliable, real-time steam trap diagnostics
Universal Trap Coverage
Supports thermodynamic, float, inverted bucket, and other industrial steam trap types
Wireless Monitoring System
Battery-powered sensors with long-range wireless communication up to 500 meters
Unique Purpose-Built Design
Engineered specifically to address the nuances of steam trap failure detection challenges
Header and Exchanger Traps
Applicable for both network distribution headers and critical heat exchanger traps
Standalone Architecture
No dependency on existing plant networks or complex control system integration
Hazardous Area Ready
Certified for safe operation in sensitive hydrocarbon and hazardous operating zones
Smart Failure Detection
Identifies leaking, choking, flooding, and non-operational traps automatically using AI
Trap Recommendation Engine
AI agents recommend optimal steam trap selection and replacement strategies based on data
Why Faclon Labs
Specialized strengths that enable effective and scalable steam loss reduction
Steam Domain Expertise
Engage experts to solve complex steam distribution and thermal challenges
Prebuilt Dashboards
Ready-to-use dashboards enabling faster deployment and value realization
Customer Success Focus
Dedicated support ensuring system reliability, user adoption, and success
Rugged Industrial Design
Built for harsh outdoor environments and demanding, high-stakes conditions
Customizable Solution
Adaptable configurations based on your specific steam network requirements
Proven Industrial Deployments
Successfully implemented across refineries, pulp, and pharmaceutical plants
CASE STUDY - STEAM TRAP MONITORING
Recovering $1M in Annual Steam Losses: Automated Failure Diagnostics for a Pharmaceutical Leader
We implemented a real-time monitoring network for over 300 steam traps across three major manufacturing sites for a leading pharmaceutical company. This digital transition replaced sporadic manual checks with a centralized diagnostic hub, providing the maintenance team with a real-time "health map" of their entire distribution network
USD 1M+ Energy Savings Potential Identified: Continuous monitoring pinpointed massive leakage volumes for immediate repair
Improved Steam Quality: Eliminating flooded traps ensured better heat transfer and overall system thermal efficiency
Reduced Manual Audit Dependency: The automated system removed the need for annual third-party ultrasonic inspections
Governance on Critical Steam Traps: Real-time alerts provided management with complete visibility over the entire network
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