Challenge

Indian Compressors Limited (ICL) needed a robust IIoT platform to monitor 100+ compressors across multiple locations. Its automation partner Masibus had the IoT hardware, but the initial Power BI implementation couldn't handle the complex visualizations and real-time data processing ICL required.

Outcome

Itanta Analytics stepped in as the pure-play IIoT platform provider, delivering a comprehensive monitoring solution that scaled ICL from monitoring 1 compressor to 100+ compressors within just 6 months—achieving complete fleet visibility, improved uptime, and centralized performance monitoring.

At a glance

• 100+ — Compressors Monitored
• 6 Months — From 1 to 100+
• 264+ — Data Tags Integrated

About Masibus & ICL

Indian Compressors Limited (ICL) is a global compressor manufacturing company established in 1943, operating a large fleet of assets across multiple locations. Masibus, ICL's automation partner, provided the IoT hardware solution, while Itanta Analytics delivered the IIoT platform powering real-time fleet monitoring.

Headquarters: India · Industry: Industrial Automation / Compressor Manufacturing · Size: Enterprise

Introduction

Industrial equipment monitoring is critical for maximizing uptime and operational efficiency. Companies with large fleets of assets need real-time visibility into equipment health, performance parameters, and predictive maintenance alerts to prevent costly downtime. Indian Compressors Limited (ICL), a global compressor manufacturing company established in 1943, needed a robust IIoT platform to monitor their fleet of 100+ compressors across multiple locations.

Masibus, ICL's automation partner, provided the IoT hardware solution but faced challenges with their initial Power BI implementation—it couldn't handle complex visualizations and real-time data processing that ICL required. Itanta Analytics stepped in as the pure-play IIoT platform provider, delivering a comprehensive monitoring solution that transformed ICL's operations from monitoring 1 compressor to 100+ compressors within just 6 months.

This case study showcases how the right IIoT platform partnership enabled ICL to achieve complete fleet visibility, improved compressor uptime, and centralized performance monitoring across their entire operation.

Pain Points in Fleet Monitoring

Before Itanta, ICL lacked the unified, real-time visibility needed to manage a growing fleet of compressors across multiple sites.

• No Live Monitoring: ICL lacked centralized visibility into compressor health across multiple assets and locations, making it impossible to monitor fleet performance and predict maintenance needs.
• Data Fragmentation: ICL's 264 data tags from compressors, sensors, and energy meters were scattered across isolated systems with no unified view of their growing compressor fleet.
• Manual Processes: ICL's staff spent time on manual processes for daily, monthly, and yearly compressor performance reports, preventing focus on proactive maintenance and fleet optimization.
• Power BI Limitations: ICL's initial Power BI solution couldn't handle complex customer visualization requests and struggled with real-time data processing from compressor sensors, causing delays in critical monitoring.
• Poor Equipment Uptime Management: Without real-time alerts and service history tracking, ICL couldn't proactively manage compressor health, leading to unexpected downtime and reactive maintenance approaches.

Highlights

• Scaled from 1 compressor to 100+ compressors monitored in just 6 months
• Integrated 264+ MQTT data tags into a single unified IIoT platform
• Replaced Power BI with purpose-built, real-time fleet dashboards
• Automated daily, monthly, and yearly compressor performance reports
• Predictive maintenance with real-time alerts to service teams

When hardware expertise from Masibus met Itanta's advanced IIoT platform, ICL achieved rapid, scalable digital transformation.

Indian Compressors Limited

A Global Compressor Manufacturer Since 1943

Indian Compressors Limited (ICL) is a global compressor manufacturing company with a large fleet of assets deployed across multiple locations. To manage a rapidly growing fleet, ICL needed real-time visibility into equipment health, performance, and maintenance needs—delivered through the Masibus-Itanta partnership.

• Established in 1943 as a global compressor manufacturing company
• Operates a fleet of 100+ compressors across multiple locations
• Generates 264+ data tags from compressors, sensors, and energy meters
• Partnered with Masibus for IoT hardware and Itanta Analytics for the IIoT platform
• Required real-time monitoring, predictive maintenance, and automated reporting at fleet scale
• Needed to move beyond Power BI's visualization and real-time processing limitations

ICL's growing fleet demanded an enterprise-grade IIoT platform capable of scaling from a single compressor to its entire operation.

System Architecture

Data Acquisition from Compressor

The process begins with continuous collection of operational parameters from the compressor, serving as the primary source of machine data.

Edge Processing via IoT Device

The data flows into an IoT Device, where it is preprocessed, filtered, and formatted for reliable transmission with minimal latency.

Central Data Management — Itanta DS Manager (MQTT Connector)

Using the MQTT Connector, data is securely transmitted to Itanta DS Manager, which acts as the central hub for managing, routing, and ensuring seamless real-time communication.

Visualization

The processed data is delivered to the Itanta Platform, where operators can access dashboards, analytics, and real-time performance monitoring tools.

Writeback Functionality

Writeback allows operators to adjust parameters or send instructions directly back to compressors via the IoT infrastructure, ensuring a closed-loop monitoring and control system.

How Itanta Transformed ICL's Operations

A Purpose-Built IIoT Platform for Fleet-Scale Monitoring

Itanta replaced ICL's limited Power BI setup with a purpose-built IIoT platform—unifying data, automating reports, and delivering real-time, color-coded fleet dashboards that scaled to the entire compressor operation.

• Centralized Fleet Command Center: Designed unified web-based dashboards giving ICL's central team complete visibility into how each compressor performs at any given time across all locations.
• Advanced IIoT Data Integration: Replaced Power BI with a purpose-built platform that integrated all 264+ MQTT data tags into a unified system capable of handling complex visualizations and real-time compressor monitoring.
• Automated Reporting & Fleet Scaling: Developed automated daily, monthly, and yearly reports with the capability to rapidly scale from monitoring 1 compressor to 100+ compressors within 6 months.
• Real-Time Dashboard System: Created comprehensive dashboards displaying live pressure, temperature, compressor status, alarms, and equipment conditions with color-coded indicators—solving Power BI's visualization limitations.
• Predictive Maintenance & Service Management: Implemented organized digital systems for service tracking, alarm logging, and real-time alerts to service teams, dramatically improving compressor uptime and operational efficiency.

The result was a scalable, real-time IIoT platform that turned ICL's compressor fleet management from reactive to proactive.

Sneak Peek into the Dashboards

ICL's dashboards deliver consolidated, real-time views of dispenser operations, daily performance, and pressure parameters across the compressor fleet.

• Dispenser Reading Dashboard: Fixed table layout displays comprehensive details for both Disp1 Hose and Disp2 Hose operations in one consolidated view. Conditional formatting uses binary indicators (0=Close, 1=Open) for filling status, bank levels, output valves, and PT01/02 system health. Real-time metrics show last fill quality, amount, flow meter totals, dispenser totals, and current gas rates.
• Daily Report Dashboard: Dynamic table format displays hourly operational data with automated calculations for suction, discharge, energy consumption, and runtime metrics. Comprehensive tracking monitors open/close values for suction, discharge, KWh consumption, and operating hours with automatic difference calculations and runtime formulas.
• Pressure Parameters Dashboard: Six pressure gauges display real-time values for Gas Inlet, Direct, High, Low, Air Compressor, and Water Pressure systems. Color-coded indicators use red, green, and yellow to instantly show high, medium, and low-pressure ranges, with live data aggregation from connected sensors.

Rapid Fleet Scaling Success

From 1 to 100+ compressors in 6 months—the Masibus-Itanta partnership delivered exactly what ICL needed: a scalable IIoT platform that transformed fleet management from reactive to proactive.

• 100+ — Compressors Monitored. Complete real-time visibility across ICL's entire compressor fleet
• 6 Months — 1 to 100+ Scaling. Rapid adoption demonstrating enterprise-grade platform scalability
• 264+ — Data Tags Unified. All MQTT data tags integrated into a single purpose-built platform
• Real-Time — Fleet Dashboards. Advanced IIoT visualizations replacing Power BI's limitations
• Predictive — Maintenance. Proactive alerts and uptime optimization replacing reactive maintenance

Conclusion

The Masibus-Itanta Analytics partnership delivered exactly what ICL needed—a scalable IIoT platform that solved Power BI's limitations and transformed their compressor fleet management from reactive to proactive.

• 1 compressor → 100+ compressors monitored in 6 months
• Power BI limitations → advanced real-time IIoT platform
• Reactive maintenance → predictive alerts and uptime optimization
• Disconnected operations → centralized fleet visibility
• Custom visualization challenges → flexible, purpose-built dashboards

When hardware expertise (Masibus) meets advanced IIoT platform capabilities (Itanta), industrial companies can achieve rapid, scalable digital transformation that delivers measurable operational improvements.

Inspired by what you've seen?

Let's explore how we can help transform your operations too. Try Itanta Analytics free for 1 month and see what real-time fleet intelligence can do for your equipment.