Stadler Anlagenbau GmbH
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Digital Maintenance

Machine data at your service

Our solutions are designed to optimize the performance of your sorting plant, leveraging machine data to reduce operational costs and maximize uptime.

Desktop monitor featuring the STADLERconnect Blockage Detection Dashboard for detecting and monitoring material blockages in waste sorting plants. The user interface displays current blockages with timestamps, colour-coded warning messages and confidence values. A STADLER sorting plant can be seen in the background.

By combining both existing and newly generated sensor data, we provide a comprehensive view of your plant's operations. Using advanced statistical analysis and AI, our tools distill complex data into clear, actionable maintenance tasks and recommendations, empowering operators to focus on their core responsibilities.

For an easy and fast monitoring

All modules in the palm of your hand

With Predictive Maintenance, we enable a proactive approach to asset management, reducing unplanned downtime and streamlining spare parts management. Our Blockage Detection module helps you to detect blockages before they occur and clear them accordingly, before they cause costly downtimes. With our Downtime Tracker we automatically track every downtime that happens in the plant including its reasons. This way, we enable you to improve your plant operations significantly in the long run. With our Maintenance Task Manager we bring all maintenance activities into one centralized view, enabling automatic scheduling and simple checklist-based execution. Our 3D Twin  gives you an interactive, photorealistic view of your entire plants, so you can quickly locate assets or e-stops, access manuals and plan retrofits remotely. Our Support Portal further enhances operational efficiency, offering access to troubleshooting resources and expert assistance.

 

A tablet and smartphone featuring STADLERconnect dashboards for the digital maintenance of waste sorting plants. The tablet displays machine condition monitoring with colour-coded warning messages, whilst the smartphone shows key performance indicators relating to plant availability, operating time and production time. A STADLER sorting plant can be seen in the background.
STADLERconnect Predictive Maintenance on various devices: desktop PC, laptop, tablet and smartphone displaying real-time machine monitoring data. Vibration sensors and a data collection gateway are shown in the foreground.

Predictive Maintenance

Operational challenge:

Unplanned maintenance events due to equipment failures cause unplanned downtime and expensive emergency repairs 

Solution and benefits: 

Early equipment failure detection through proactive condition monitoring, enabling predictive maintenance planning 

  • Increased uptime 

  • Reduced maintenance costs 

  • Extended equipment lifespan 

  • Enhanced sorting performance 

STADLERconnect Blockage Detection on desktop PC, laptop, tablet and smartphone. The user interface displays detected material blockages in sorting plants, including status indicators, timestamps and color-coded warning messages.

Blockage Detection

Operational challenge: 

Short-term plant downtimes and equipment damage due to undetected blockages 

Solution and benefits: 

Machine data monitoring of all relevant conveyors simultaneously to automatically detect material blockages on conveyor belts 

  • Improved operational efficiency with reduced downtime 

  • Deeper insights for strategic plant optimization 

  • Extended plant lifespan through reduced wear and tear 

STADLERconnect Downtime Tracker on desktop PC, laptop, tablet and smartphone. The user interface displays key performance indicators for plant availability, operating time and production time, as well as a detailed overview of downtime events, including their causes, duration and timeline.

Downtime Tracker

Operational challenge:

High downtime costs due to missing overview of downtimes and their reasons 

Solution and benefits: 

Automatic calculation of technical availability and plant utilization with KPI and statistics visualization 

  • Increased transparency on downtime occurrence and location 

  • Automated and real-time tracking without manual data entry 

  • Smoother plant operation through reduced troubleshooting 

  • Improved plant uptime 

STADLERconnect Maintenance Task Manager displayed on a desktop PC, laptop, tablet and smartphone. The user interface shows maintenance tasks for sorting plant equipment, including task descriptions, status, assigned personnel, due dates and priorities, enabling centralised maintenance planning and management.

Maintenance Task Manager

Operational challenge: 

Lower plant availability and efficiency due to inadequate maintenance management. 

Solution and benefits: 

Centralized task management in a simple, digitalized checklist style overview including targeted notifications. 

  • Reduced downtime with improved planning and scheduling 

  • Increased machine efficiency and less administrative work 

  • Implementation of STADLER maintenance tasks and intervals without need for extensive manual set-up 

  • Increased transparency with centralized maintenance documentation 

STADLERconnect 3D Twin displayed on a desktop PC, laptop, tablet and smartphone. The interface shows an interactive 3D view of a recycling sorting plant with detailed equipment visualisation and asset information.

3D Twin

Operational challenge: 

Limited visibility and orientation within complex plant environments make it difficult to quickly locate critical equipment, such as e-stops. 

Solution and benefits: 

An interactive, as-built 3D representation of the plant that enables intuitive navigation and allows users to quickly search for and locate equipment. 

  • Faster orientation and troubleshooting 

  • Reduced on-site visits with efficient remote planning and training 

  • Centralized documentation access directly linked to equipment 

STADLERconnect Support Portal on desktop PC, laptop, tablet and smartphone. The user interface displays an overview of support tickets, including ticket numbers, issue descriptions, processing statuses and priorities, as well as features for searching and creating new support requests.

Support Portal

Operational challenge:

Missing overview of ongoing and solved After-Sales cases. 

Solution and benefits: 

Direct connection to out After Sales 

  • Overview of all After-Sales tickets 

  • Direct communication with our After-Sales ticket system 

Data-driven insights from our modules ensure better personnel logistics, simplified maintenance, and smoother plant operations overall.

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