Proactive Condition Monitoring

Move From "Run-to-Failure" to True Predictive Maintenance

In high-stakes industrial environments, manual inspections are no longer enough. Walking the plant floor with a handheld thermal camera once a month leaves you vulnerable for the other 719 hours of the month.

The Reality of Reactive Maintenance:

Unplanned Downtime: A single bearing failure can halt an entire production line, costing thousands per minute.

Catastrophic Safety Risks: Arc flashes and electrical fires often happen without visible warning signs.

Inefficient OEE: Your Overall Equipment Effectiveness plummets when you are constantly fighting fires instead of optimising production.

The Solution: Cape Thermal implements fixed radiometric thermal sensors that watch your assets 24/7/365. We don't just take pictures; we stream temperature data directly to your control room, allowing you to predict failures weeks before they happen.

Intelligent Monitoring. Instant Alerts

Our systems are designed to integrate seamlessly into your existing OT (Operational Technology) network.

Continuous Radiometric Streaming: Unlike standard security cameras, our sensors measure the temperature of every pixel in the frame. Whether it’s a high-voltage switchgear cabinet or a conveyor belt roller, we track thermal trends in real time.

Automated alarming logic: Set multiple thresholds (e.g., "Warning" at 60°C, "Critical" at 80°C). If an asset exceeds these limits, the system instantly triggers an alarm via email, SMS, or a relay output to your PLC.

Region of Interest (ROI) Analytics: We define specific zones within the camera's view to monitor critical components while ignoring background heat sources, ensuring zero false alarms.

Seamless Integration: Our solutions support industrial protocols (Modbus TCP, MQTT, and ONVIF) to feed temperature data directly into your SCADA, BMS, or existing video management system (VMS).

Where We Deploy Thermal Monitoring

Electrical Substations & Switchgear: Detect loose connections, unbalanced loads, and corrosion in busbars before they cause an arc flash or outage.

Key Benefit: Non-contact monitoring of high-voltage equipment behind safety glass.

Mechanical Assets (Motors, Pumps, Bearings): Friction generates heat long before vibration sensors pick up a mechanical fault. Identify lubrication issues and misalignment early.  

Key Benefit: Extend asset lifecycle and plan maintenance during scheduled shutdowns.

Critical Vessel & Tank Monitoring: Monitor the integrity of refractory linings in kilns, furnaces, and boilers. Detect insulation breakdowns to prevent dangerous breaches.

Data Centres & Server Rooms: Monitor server rack intake/exhaust temperatures to optimise cooling efficiency (PUE) and prevent hardware overheating.

Why Industry Leaders Choose Cape Thermal

We are not just box movers. We are system-agnostic thermal integrators.

Most suppliers will try to force-fit a specific brand they represent. At Cape Thermal, we audit your facility first, then specify the exact sensor technology that fits your environment—whether that's Raything, Axis, Dahua, or Teledyne FLIR.

South African Expertise: We understand local industrial challenges, from load-shedding/power-surge-related damage to harsh mining environments.

End-to-End Support: From the initial thermal audit to installation, calibration, and control room integration.