May 6, 2026
The growing presence of IoT sensors in industrial settings, particularly in sugar and ethanol plants, points to a significant transformation in monitoring and optimization processes. To analyze the role of these devices, it is necessary to briefly review their origins and the evolution of industrial instrumentation.
The use of sensors in industry dates back to the Second Industrial Revolution in the late 19th century, when mechanical systems began to incorporate measuring instruments for pressure, temperature, and other variables. Advances in electronic technologies during the 1950s and 1960s led to the emergence of wired sensors—initially connected to local control panels and, later, to supervisory control and data acquisition (SCADA) systems by the 1980s. From that point on, digital sensors gained ground, offering higher levels of precision and reliability, though they remained dependent on wired infrastructure.
As automation has advanced, real-time optimizers have also emerged—true “autopilots” capable of adjusting process variables and ensuring maximum operational efficiency.
IoT sensors are currently playing an increasingly prominent role in industrial settings. These wireless devices are easy to install and cost-effective, enabling comprehensive monitoring of a wide range of equipment. This combination of features often leads to requests to “equip” equipment with IoT sensors—that is, to configure systems to halt operations in the event of any abnormal parameters. There are even articles published on the topic (click here).
However, it is essential to understand that the response time of IoT sensors—from event detection to corrective action—is typically longer than that of traditional wired sensors. In security applications—those involving personal safety or the protection of equipment—the use of wired sensors remains indispensable. In less critical situations, however, the adoption of IoT sensors can be considered, always following an analysis of the risks involved.
The main causes of industrial equipment failures can be categorized as follows:
Among these factors, random events are the least controllable, while the others can be mitigated through monitoring, maintenance, and training.
When choosing between wired sensors and IoT sensors, one must consider both the potential impact of failures and the frequency with which they occur. If the risk involves safety or severe damage, wired sensors are essential. If the goal is to prevent wear and tear or non-critical failures, IoT sensors are a viable alternative, provided they are supported by a detailed analysis of the situation.
The Future: Integrating Asset Performance and Health
The main challenge—and also the greatest opportunity—lies in integrating production systems with the health monitoring of industrial assets. Currently, most sensors connected to supervisory systems are used for operational decision-making, prioritizing production metrics and relegating asset health to the background. The analogy is clear: focusing solely on production is like running without monitoring your heart rate.
The adoption of IoT sensors enables the integration of real-time optimization algorithms with information on equipment condition. This makes it possible to make decisions not only based on performance, but also taking into account the actual wear and tear of the assets.
Continuous, intelligent asset monitoring, combined with operational adjustments based on this data, extends equipment lifespan and reduces the incidence of premature failures in components such as bearings and couplings. The direct benefits include fewer unplanned shutdowns, reduced waste, improved safety, and greater operational predictability.
Conclusion: The evolution of industrial monitoring points to a scenario where the intelligence of IoT sensors will be essential not only for tracking operational variables but also for preserving and optimizing the useful life of industrial assets. Using equipment health indicators alongside production indicators will be essential for more efficient, safer, and competitive industries.
