Plants where utilities are measured per line, and faults are fixed before they stop one.
Compressed air, steam, process water and motors stop a line or quietly double its cost. Aqueduct meters them per line and asset, flags drift before a stop, and routes the fix into your CMMS.
What manufacturing units teams are up against.
Water, energy, air and operations carry equal weight. Each one runs the same loop: monitor, measure, identify, act, verify.
Water: Process water and cooling towers
Blowdown and passing valves hidden in the intake total
Energy: Compressed air network
Leaks loading compressors through weekends and shift changes
Air: Steam distribution
Failed traps sending live steam to the condensate return
Operations: Critical rotating equipment
Bearing wear unseen until a motor trips
Problem, solution, impact.
How Aqueduct resolves each problem for manufacturing units, and what changes when it does.
Blowdown and passing valves hidden in the intake total
A live water balance across meters and sub-meters localizes the loss, routes the fix and confirms it closed at the meter.
Loss found from the balance, not the bill, and every fix verified.
Leaks loading compressors through weekends and shift changes
Weather-normalized baselines per building and asset show the waste in money; schedules and setpoints adjust where control is enabled.
Savings stated in money and confirmed at the meter, not estimated.
Failed traps sending live steam to the condensate return
Air quality per zone, overlaid with occupancy, with ventilation raised when it matters and verified back in range.
Targets held during occupied hours, with the energy cost counted.
Bearing wear unseen until a motor trips
Faults diagnosed in plain language and routed into your CMMS with the fix; early signs of failure schedule maintenance first.
Fewer reactive call-outs and closures confirmed by the equipment.
One incident, from first signal to verified fix.
An illustrative example of the flywheel on a typical site.
Compressors, boilers, pumps and feeders read, SCADA read only.
A baseline per line, shift and asset.
Compressor 2 loaded on a Sunday with production stopped.
Leak survey ticket with the flow profile.
Weekend load back to baseline. Saving priced.
Four connected products on one data layer.
Replace what should be replaced. Connect the rest.
- Utility monitoring
- EMS
- Leak and balance tools
- Plant air quality monitoring
- CMMS and EAM
- SCADA and historians, read only
- ERP for cost allocation
Three equal ways in: keep your BMS, replace it, or build Aqueduct in at design stage.
The questions each seat asks first.
“Will it prevent an unplanned stop?”
“Does it work with our CMMS?”
“Can I show the real exposure curve?”
Standards and regulations we supply evidence for.
We supply the measured inputs. You run the program and file the report.
Guides for FMCG and process plants
FMCG campuses
Water, power, steam and air measured per business unit, ranked by use per tonne or litre.
Learn moreCompressed air and steam
Leak load, specific power, failed steam traps and condensate return, priced per month.
Learn moreProcess water and utilities
A live process water balance to ZLD, with power factor and maximum demand per feeder.
Learn moreWhat utility failures cost a plant.
of a compressor’s output can leak away; proactive repair gets it under 10%.
Source: Compressed Air Challengeof steam traps may fail in systems left unmaintained for 3 to 5 years.
Source: US DOE Steam Tip Sheetlost each year to unplanned downtime by the 500 largest companies.
Source: Siemens, 2024Stops are getting longer, and teams are responding.
Recovery takes longer
Siemens found average recovery from a stop rose from 49 to 81 minutes, and almost half of manufacturers now run a predictive maintenance team.
Leaks found from the weekend baseline
Compressor load with production stopped is the leak load, measured without a survey.
Sources3 references cited on this page
Proven in live sites across sectors.
Anonymized results from live sites.
sites in 21 countries run on Aqueduct.
and 9 clinics in one of India’s top hospital chains.
US airport running water intelligence on Aqueduct.
of commercial real estate under Aqueduct.
Features that matter here
Common questions
No. Aqueduct reads SCADA, PLC and historian data read only, and production control stays with your systems. Utility equipment such as exhaust fans can be scheduled through separate relays or field devices only with owner approval, and every command is logged.
Yes. Aqueduct meters water, power, steam and compressed air per line and divides them by the output your plant shares, so each product carries its measured utility cost. Monthly allocations export to your ERP. See sub-metering by production line.
Often, yes. aQ PredictIQ reads vibration, temperature and power on rotating equipment, flags drift from each asset's own normal well before a trip, and schedules the work in your CMMS. Lead time depends on the failure mode and the sensors fitted. See predictive maintenance.
With the utility that costs the most and is measured least, usually compressed air, steam or process water. Aqueduct meters that system first, sets a baseline per line and prices each finding, then extends the same model to the next utility and the next plant. See compressed air and steam.
See Aqueduct on your own facility.
Bring a site, a utility bill or a question. We will show you where the loss is.