Embitel is a leading player in the design and development of Industrial IoT applications. With an exclusive suite of IIoT application development services, we can streamline the operations of your IoT infrastructure and add quantifiable value to your business use cases.
Our customers vouch for our solutions as they have the ability to streamline daily operations by integrating automation and connectivity into the industrial infrastructure.
We offer you diligent support from the requirements gathering and engineering phases, to maintenance and evolution stages. Our dedicated hardware and software support teams ensure the most optimum integration of technologies so that your custom-designed Industrial IoT solution offers unbeatable performance.
What are Industrial IoT Applications?
Industrial IoT applications are flexible technology platforms designed for automation, data collection, processing, and providing actionable insights for smart decision-making in Industry 4.0.
An IIoT system strengthens your push to achieve operational efficiency by integrating industrial machinery with a network of IIoT sensors and software.
The versatile nature of IIoT applications makes them go-to solutions for integrating device-to-device and device-to-network connectivity.
How do Industrial IoT Applications Operate?
IIoT applications operate through a multi-layered architecture that consists of five primary components:
Edge Layer – Data Collection
The edge layer in the IIoT ecosystem consists of sensors, actuators, and edge devices that collect data from industrial equipment and the environment.
- Sensors: Devices that detect changes in physical conditions like temperature, pressure, vibration, humidity, and gas levels.
- Actuators: Devices that interact with machines based on received signals, such as motors, valves, and robotic arms.
- Industrial Gateways: Convert IIoT sensor data into machine-readable digital signals and transfer it to the cloud or local processing systems.
Connectivity Layer – Industrial Communication
Industrial IoT Applications rely on both - wired and wireless communication protocols to transmit data from devices to a central system.
- Wired Protocols
- Ethernet/IP: Reliable for real-time industrial automation.
- PROFINET: Widely used in factory automation.
- Modbus TCP/IP: Common for connecting industrial controllers and PLCs.
- Wireless Protocols
- Wi-Fi (IEEE 802.11): Used for short-range communication.
- LoRaWAN: Low-power, long-range communication for remote sensors.
- 5G & LPWAN: Emerging technologies enabling ultra-fast and low-latency communication.
Edge Computing & Processing
Transmitting entire data to the IoT cloud could result in latency issues. To combat this, industries use edge computing. It enables real-time data processing at or near the device. IIoT devices compute data in the following ways:
- Edge AI: Uses machine learning algorithms on edge devices to detect anomalies in industrial machines.
- Fog Computing: Data is pre-processed at intermediate nodes before reaching the cloud.
Cloud Computing & Big Data
IoT Cloud platforms provide centralized data storage, analysis, and decision-making capabilities for industrial systems.
- Big Data Analytics: Machine learning models analyze large datasets for trends and predictive insights.
- Digital Twins: This is a virtual replica of an industrial system that helps in simulation and real-time monitoring.
- Industrial IoT Platforms: AWS IoT, Microsoft Azure IoT, and Siemens MindSphere enable cloud-based IIoT solutions.
Application Layer – Industrial Software & AI
This layer includes user interface development, control applications, and AI-driven decision systems that help operators monitor and control industrial processes.
Industrial IoT Applications – Features
Predictive Maintenance
IoT-powered predictive maintenance solutions leverage real-time sensor data and advanced analytics to monitor equipment health. By analyzing these factors, businesses can predict potential failures before they occur, reducing unexpected downtime and costly repairs.
This proactive approach extends equipment lifespan and improves overall productivity.
Real-Time Monitoring
Continuous monitoring of industrial assets, processes, and environmental conditions ensure optimal performance. IIoT sensors collect and transmit real-time data to centralized dashboards, allowing operators to track efficiency, detect anomalies, and make informed decisions instantly. This is particularly beneficial in industries such as manufacturing, energy, and logistics.
Quality Assurance
Industrial IoT Applications facilitate quality control by integrating automated inspection systems and AI-driven analytics. IoT sensors detect defects, inconsistencies, and deviations from production standards in real-time, reducing waste and ensuring that only high-quality products reach the market.
This leads to higher customer satisfaction and compliance with regulatory requirements.
Automation
Industrial IoT applications enable intelligent automation by connecting machines, robotics, and control systems. Smart factories leverage IIoT for autonomous operations, self-optimizing production lines, and robotic process automation (RPA). This reduces human intervention, increases throughput, and minimizes errors in repetitive tasks.
Data Analytics
With vast amounts of operational data generated by IIoT devices, advanced data analytics and AI-driven insights play a critical role in decision-making. Businesses use big data analytics to identify inefficiencies, optimize workflows, forecast demand, and streamline resource allocation for better productivity.
Safety Monitoring
IIoT enhances workplace safety by detecting hazardous conditions, monitoring worker health, and ensuring compliance with safety protocols. Wearable IoT devices track vital signs and alert supervisors in case of emergencies, while environmental sensors detect gas leaks, excessive heat, or unsafe machine operations to prevent accidents.
Energy Management
Energy consumption optimization is a key benefit of IIoT applications. Smart sensors track electricity, water, and fuel usage, identifying patterns and inefficiencies. Automated energy management systems adjust settings in real time to reduce waste, lower operational costs, and support sustainability initiatives.
Significance of Industrial IoT Applications in a Digitally Connected World
Industrial IoT applications are powered by technology to improve business efficiency. They automate and streamline existing processes and offer an intuitive HMI (Human-Machine Interface) that connects the user to the digital world. Users are hence, empowered to control connected devices effortlessly.
IIoT end-user applications can be customized to store information in databases. This data can subsequently be displayed on a unique dashboard that offers insights into the functioning of the connected devices.
Customized desktop applications find extensive use in an industrial landscape. Some of the use cases include applications that test high-voltage instruments and quality control applications.
Industrial IoT applications may also be developed for the remote monitoring and automated control of solar panels in a solar energy plant. Predictive maintenance is a significant benefit offered by IoT in an industrial setup.
It is possible to monitor connected equipment and predict the occurrence of faults, so that maintenance activities commence on time. This also mitigates outages due to equipment failure and subsequently, saves on maintenance costs.
Applications of IIoT in the Mining Industry
Industrial IoT (IIoT) applications enhance safety, efficiency, and compliance in the mining industry. How?
- Wearable IIoT sensors, such as smart helmets and vests, monitor miners’ health and detect hazardous gas exposure.
- Air quality and gas detection systems continuously track methane, CO₂, and particulate matter, preventing accidents.
- Automated emergency alerts enable real-time notifications for equipment failures, gas leaks, or structural instability, ensuring quick responses.
- Remote equipment operation allows centralized control of mining machinery, improving productivity and reducing on-site risks.
- IIoT sensors aid regulatory compliance by providing accurate environmental data, ensuring adherence to safety and environmental standards.
IIoT Applications in the Construction Industry
The Industrial Internet of Things revolutionizes construction by enabling intelligent monitoring and automation.
Structural integrity monitoring utilizes IIoT sensors to assess building stability in real-time, detecting potential failures and enhancing earthquake resistance. This ensures safety and compliance with structural standards.
Meanwhile, smart building automation integrates IIoT to optimize HVAC, lighting, and security systems to reduce energy consumption and operational costs.
IIoT Applications for Automotive Industry
Industrial IoT desktop applications can be used to evaluate electrical components of EVs, test music systems, and perform quality control in automotive manufacturing facilities. IoT based dongle applications can be developed for internal and external battery management of vehicles and telematics functions.
Applications of Industrial IoT in the Healthcare Industry
The use cases of IIoT applications in the healthcare industry include equipment for telemedicine, apps for remote monitoring of patients, connected medical devices, wearables for detecting heartbeat/distance traveled/calories burnt, etc.
In the pharmaceutical industry, Industrial IoT apps can be developed to monitor medication temperature and to ensure that the medicines adhere to quality standards during transportation.
Pick IIoT Services Based on Your Requirements
Listed below are Embitel’s services in Industrial IoT applications development:
Custom Industrial IoT app development based on a vision
- Our IIoT team experts help you in bringing your vision of a customized IoT application to reality.
- We assist in architecture design and choice of technology stack.
- Elaborate product development roadmap is then created for tracking progress.
- Development, testing and QA activities are executed, adhering to Agile project development methodologies.
Customized app development from well-defined requirements
- Our team of consultants assist in the design and development of the IoT application based on project requirements.
- We also assist in integrating the product in an IoT framework.
- Security and scalability of the IoT applications are given utmost importance throughout the SDLC.
Upgrade and maintenance of existing IIoT applications
- We assist you in upgrading your connected industrial IoT applications to state-of-the-art technology.
- We have immense experience in executing long-term projects for sequential upgrades and maintenance of IoT applications in Industry 4.0.
Mobile App and HMI Development for Healthcare Technology Company
Business Challenge:
The customer envisioned a scalable Android mobile application solution for healthcare professionals to manage the medical conditions of patients and perform data analysis. They also desired the implementation of custom controls that were not available in off-the-shelf solutions.
Embitel Solution:
We developed an Android-based mobile app that had a host of features, including tracking of vital body parameters, sleep monitoring, consolidation of medication logs, nutrition tracking, offline operation, integration of third-party services, data dashboard with graphical results, guidance on lifestyle changes, appointment logging, etc.
Embitel Impact:
Our IoT mobile application, which integrated with the cloud to provide an end-to-end health monitoring solution with custom controls and scalability features, transformed the customer’s vision to reality.
Mobile App Development for Industrial Drive Controller Application
Business Challenge:
The customer’s existing industrial automation solution supported limited controls, and manual intervention was necessary. This was also prone to human errors.
Moreover, the existing legacy app did not provide visual feedback of the deployed motors and the associated working conditions. There was a pressing need for IoT app development to monitor the industrial equipment.
Embitel Solution:
Our Automation and Mobility team designed and developed a mobile application with remote monitoring capabilities, operator-centric HMI design and custom control features.
Embitel Impact:
The mobile app solution ensures that statuses of deployed motors are visible to operators in real-time.
Update of Existing Software Solution for a Leading Medical Device Manufacturer
Business Challenge:
The customer desired to update the software solution of a medical device product line to address limitations and improve features.
Embitel Solution:
Our team delivered a cutting-edge solution with features such as multi-language support, rollback of firmware update versions, enhanced security, custom maintenance schedule, and enhanced user interface. Our customized development process followed FDA guidelines as well.
Embitel Impact:
We were able to provide an innovative business solution for the various challenges faced by the customer.
