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Predict Faults & Breakdowns Before They Happen

Condition Monitoring for Motors

Tired of maintenance programs that consume time and budget without preventing failures? UpTime combines industrial-grade 3-in-1 sensors with intelligent software and expert-led prescriptive analytics to eliminate unplanned downtime in critical motor assets.

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Validated by Reliability & Maintenance Professionals

"UpTime Solutions has installed in our facility what is likely the largest wireless installation of its kind in the world – approximately 20,000 sensors over 3 million square feet. Our payback has been tremendous. We estimate a 30% reduction in downtime and a payback period of less than one year. The level of support we receive is tremendous.”
Facility Mgr. & System Maintenance Engineering
Facility Mgr. & System Maintenance EngineeringFortune 500 Material Handling Company
“We looked at several different technologies and we selected UpTime as our vendor of choice because of their demonstrated ability to wirelessly monitor slow-speed assets. We found their solution to be unique in the industry, and they have been very responsive to our needs. We anticipate growing with them over the next several years to cover more and more assets in the future.”
Senior Director of Asset Health
Senior Director of Asset HealthFortune 500 Pulp & Paper Company
“We rely on UpTime Solutions to provide us with detailed actionable intelligence to direct our maintenance work orders. We were looking for a solution that provides us with more than an alert or an alarm. We need to know what specifically is the emerging failure mechanism with a piece of equipment and the timeframe is in which we have to address it. UpTime has provided us with those details, which saves our maintenance team time and money, and creates better floor-level buy-in to support the program.”
Project Engineer
Project EngineerFortune 500 Pulp & Paper Company
“I’ve worked with a lot of predictive maintenance providers during my career. As an independent contractor, I get to choose who I will install and recommend to my clients. The UpTime equipment is the best in terms of capabilities and data quality. I don’t hesitate to recommend them to my clients, and they are experts in their field.”
Owner & Independent ContractorReliability & Maintenance Services

The Advantage of UpTime’s Motor Condition Monitoring

Earliest Detection With 3-in-1 Motor Sensors

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In 2019, we introduced the world’s first wireless sensor combining ultrasonic, vibration, and temperature detection, and we’ve been raising the bar ever since. Today, our solutions deliver actionable insights that keep critical assets running efficiently and downtime to a minimum.

Industry-Specialized Expert Analysts

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While AI can help identify patterns and detect abnormal signatures, only UpTime provides live analysts who review alerts, pinpoint the issue, and prescribe corrective action. With decades of industry experience, our experts have worked with motors and rotating equipment across nearly every sector.

Prescriptive Work Orders in Your CMMS

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UpCast can seamlessly integrate with your CMMS and EAM systems to improve asset tracking and streamline maintenance operations. Alerts are prioritized and delivered directly to your team, along with prescriptive work orders in your CMMS, enabling faster planning and more efficient allocation of time and resources for repairs.

ISO 9001 & 27001 Certified

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Security and quality are at the heart of everything we do. UpTime Solutions is ISO 9001 and 27001 certified, underscoring our commitment to rigorous quality management and robust information security. With us, you can trust that your facility’s privacy is safeguarded and your assets are protected.

A Comprehensive Ecosystem for Monitoring Motor Health & Function

MistEX & MistLX

Wireless sensors for monitoring ultrasound, vibration, and temperature, designed for scalable deployments and large-scale rollouts.

MistLX: Compact, rugged design with a small form factor for versatile mounting.

MistEX: High-performance model with extended battery life (up to 5 years).

Key features of both models:

  • Bluetooth connectivity to UpCastCM, UpTime’s cloud platform
  • IP69-rated for maximum protection
  • Optional stainless steel housing for wet, high-moisture, or washdown environments

Brick T1SX

Hybrid wireless sensor that integrates existing wired inputs into UpTime’s platform — no batteries or extra infrastructure required.

Key Features:

  • Powers and reads up to 15 sensor inputs
  • Converts junction boxes or accelerometers into wireless data hubs
  • Long-range 900 MHz wireless connectivity with no battery swaps
  • Wirelessly transmits data from up to 7 accelerometers and 7 process channels (+tach)

UpCast

Cloud-based platform connecting all UpTime sensors to deliver real-time vibration, ultrasound, and temperature insights. Smart analytics turn data into actionable alerts, prescriptive work orders, and prioritized maintenance.

Key Features:

  • Highly accurate diagnostics and alerts
  • Prescriptive work orders ranked by severity
  • Easy integration with third-party systems and Active Directory
  • Scalable, enterprise-grade platform
Learn More About Our Solutions

3-in-1 Condition Monitoring for Motors

Featuring MistEX & MistLX – The Ultimate Asset Watchdogs

Ultrasound

Using high-frequency sound-wave readings, ultrasonic condition monitoring identifies motor faults that often appear weeks or even months before changes in temperature or vibration are detectable. UpTime uses ultrasound as a first line in the defense against downtime and wasted maintenance effort.

Vibration

With vibration monitoring, each machine’s unique vibration signature provides a clear picture of its health and operating efficiency. While preventive maintenance programs can lead to overmaintaining motors and still result in breakdowns, UpTime equips your team with the tools to detect issues early and prevent unplanned downtime.

Temperature

Relying solely on an overload relay means motor issues are often detected only after excessive current and heat are already present. UpTime’s Mist sensors track readings up to 175°F and correlate them with vibration trends, while our software stores and analyzes patterns over time, enabling earlier, more accurate fault detection.

Ultrasound Detects

Overheating Conditions

  • Sustained high motor temperatures
  • Rapid rise under normal load
  • Hot spots on motor housings

Leak & Flow Analysis

  • Compressed air and gas leaks
  • Steam trap failure (Blow-through)
  • Internal valve bypass detection

Electrical Reliability

  • Corona discharge in high-voltage cabinets
  • Electrical arcing and tracking
  • Partial discharge signatures

Earliest Stage Bearing Wear

  • Sub-sonic friction changes (Stage 1)
  • Turbulence in high-speed bearings
  • Metal-to-metal contact signatures
Vibration Detects

Bearing & Rotor Health

  • Inner and outer race bearing defects
  • Rotor bar faults in induction motors
  • Shaft imbalance and eccentricity

Mechanical Alignment

  • Parallel and angular misalignment
  • Soft foot conditions
  • Coupling wear and degradation

Structural Integrity

  • Mechanical looseness in housings
  • Resonance and critical speed issues
  • Foundation and mounting stability

Transmission Components

  • Gear mesh frequency anomalies
  • Belt and pulley wear patterns
  • Driven equipment vibration transfer
Vibration Detects

Precision Lubrication

  • Acoustic feedback for optimal greasing
  • Over-lubrication detection
  • Under-lubrication friction peaks

Bearing Issues

  • Heat from bearing friction
  • Lubrication breakdown
  • Temperature peaks before noise

Electrical Faults

  • Winding insulation degradation
  • Phase imbalance/Single phasing
  • High resistance connections

Load & Process Problems

  • Motors running out of the design load
  • Misaligned driven equipment
  • Increased torque from process changes

How To Sign Up for a Pilot Trial for Our Motor Condition Monitoring System

On average, our customers report payback within 2–12 months, with more than a 3x reduction in unplanned downtime. Ready to see the results for yourself? Try our pilot. 

Reliability Assessment

Consult with our sales team to determine whether our system is a good fit for your facility.

Installation & Setup

We arrive on-site with everything we need to set up your motor condition monitoring system.

Expert Support & Review

Our analysts monitor your assets, issue alerts and work orders for abnormal readings, and provide monthly consultations to optimize your maintenance program.

Benefits of Motor Condition Monitoring

Prolonged Equipment Lifespan

By identifying maintenance issues before they escalate into failures, motor condition monitoring helps reduce or eliminate catastrophic breakdowns, which may drive excessive, unplanned wear and costly damage to critical equipment. Acting early extends asset service life, avoids emergency replacements, and significantly lowers repair and parts costs. For many UpTime customers, these avoided failures and efficiency gains translate into a measurable return on investment within just 3 to 12 months, while ensuring the long-term protection of capital investments.

Improved Maintenance Efficiency

Condition-based monitoring strengthens maintenance programs by eliminating the inefficiency of waiting for issues to appear on a fixed schedule. With UpTime, motor condition monitoring data is reviewed by expert reliability analysts who offer ongoing consultation to help facilities prioritize the right maintenance at the right time. Rather than reacting to raw alerts, teams can restructure their maintenance programs around validated insights, which helps reduce unnecessary work and avoids the over-maintenance of healthy assets.

Optimized Spare Parts Planning

Sensor-based motor condition monitoring generates high-value data that delivers deeper insight into true maintenance demands over time. UpTime’s 3-in-1 sensors combine ultrasonic, vibration, and temperature monitoring to detect developing issues well before they escalate into parts-consuming breakdowns. With this early visibility, maintenance teams can plan interventions proactively, forecast inventory needs with greater accuracy, reduce excess “just-in-case” stock, and ensure critical spare parts are available precisely when they’re needed.

Enhanced Operational Consistency & Quality

Motor condition monitoring sensors detect subtle changes in equipment performance that may not immediately trigger maintenance events but can impact product consistency and quality. With UpTime, real-time and historical data are continuously reviewed by expert reliability analysts who provide ongoing maintenance consultation and translate insights into actionable maintenance work orders directly within the platform.

Industries We Support with Motor Condition Monitoring Solutions

Pulp & Paper

Wireless Condition Monitoring
for Pulp & Paper

High humidity, abrasive materials, and non-stop equipment demands are just part of daily life in pulp and paper facilities. These conditions put machinery—like presses, rollers, and conveyors—at risk of overheating, misalignment, and wear.

UpTime’s wireless condition monitoring provides real-time insights into equipment health, helping you avoid breakdowns, extend machinery life, and keep production on track—even in the harshest conditions.

Industrial

Wireless Condition Monitoring
for Industrial

Industrial equipment in refineries, distribution centers, and wastewater treatment plants works continuously under heavy demands. Complex machinery setups, frequent start-stop cycles, overworked motors, and unplanned downtime can quickly disrupt operations.

UpTime’s wireless condition monitoring spots early warning signs of trouble—like rising temperatures or abnormal vibrations—so you can resolve issues before they escalate and keep productivity high.

Logistics

Wireless Condition Monitoring
for Logistics

Every second counts in logistics, where seamless workflows and on-time deliveries are non-negotiable. But conveyor systems and automated equipment are prone to breakdowns and interference from foreign object debris (FOD).

UpTime’s wireless condition monitoring solutions provide proactive monitoring to detect misalignments, FOD, overheating, or other issues early—helping you avoid delays and keep your supply chain moving seamlessly.

Mining

Wireless Condition Monitoring
for Mining

Mining operations push heavy-duty machinery to the limit, with heavy loads, harsh environments, slow-moving components, and relentless schedules. Unplanned downtime not only halts production but can also put worker safety at risk.

UpTime’s wireless condition monitoring solutions help you catch problems early—like worn bearings, overheating components, or abnormal vibrations—so your equipment stays reliable, and your teams stay safe.

Food & Beverage

Wireless Condition Monitoring
for Food & Beverage

In food and beverage production, even minor equipment failures can ripple into major delays, lost product, or compliance risks.

UpTime’s wireless condition monitoring helps you stay ahead of the curve by detecting issues like air leaks, overheating, or vibration changes before they cause disruptions—keeping your lines moving and your standards high.

Automotive

Wireless Condition Monitoring
for Automotive Manufacturing

Automotive production thrives on speed and precision—but downtime on your production line can throw everything off schedule.

UpTime’s wireless condition monitoring helps you keep pace with demand by identifying potential failures early, such as overheating motors, unbalanced conveyors, or leaks in compressed air systems, so you can maintain uptime and stay ahead.

Pharmaceutical

Wireless Condition Monitoring
for Pharmaceutical Production

Pharmaceutical facilities depend on precision and compliance. Equipment failures, whether in cleanrooms or production lines, can mean wasted product, missed deadlines, or regulatory fines.

UpTime’s wireless condition monitoring gives you the tools to ensure consistent operations by catching issues like rising temperatures, misaligned components, or air leaks before they affect your production.

Consumer Packaged Goods

Wireless Condition Monitoring
for Consumer Packaged Goods

Meeting demand in the CPG industry requires production lines to run smoothly, often at high speeds and with little margin for error. Equipment like conveyors, rotary fillers, and packaging lines face constant strain, increasing the risk of misalignment, overheating, or air leaks.

UpTime’s wireless condition monitoring detects these issues in real time, helping you prevent unplanned downtime, maintain efficiency, and deliver on customer expectations without disruptions.

Power Generation

Wireless Condition Monitoring
for Power Generation

Power generation relies on critical equipment—like turbines, generators, and transformers—running smoothly to meet demand.

UpTime’s wireless condition monitoring tools identify issues such as overheating, abnormal vibrations, and component wear early, ensuring reliable energy production and preventing costly downtime.

Manufacturing

Wireless Condition Monitoring
for Power Generation

Power generation relies on critical equipment—like turbines, generators, and transformers—running smoothly to meet demand.

UpTime’s wireless condition monitoring tools identify issues such as overheating, abnormal vibrations, and component wear early, ensuring reliable energy production and preventing costly downtime.

Aerospace

Wireless Condition Monitoring
for Power Generation

Power generation relies on critical equipment—like turbines, generators, and transformers—running smoothly to meet demand.

UpTime’s wireless condition monitoring tools identify issues such as overheating, abnormal vibrations, and component wear early, ensuring reliable energy production and preventing costly downtime.

Oil & Gas

Wireless Condition Monitoring
for Power Generation

Power generation relies on critical equipment—like turbines, generators, and transformers—running smoothly to meet demand.

UpTime’s wireless condition monitoring tools identify issues such as overheating, abnormal vibrations, and component wear early, ensuring reliable energy production and preventing costly downtime.

Gain the clarity you deserve

Protect your line’s bottom line by maximizing the ROI on your capital equipment.

Ready to get every ounce of value from your assets? Let’s talk.