From Pilot to Standard: The SENSAiO 2025 Industrial Report

A review of how 2,600 sensors and a 2x growth trajectory redefined wireless infrastructure in hazardous zones.

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The Deployment Data: What the Industry Bought  

The Analysis:

  • Valve Positioning (57%): This solution delivers the highest ROI for our clients. By digitizing manual valves, operators effectively prevent leaks caused by misalignment and significantly optimize manpower by eliminating the need for frequent manual rounds. Our patented clamp-on design allows for installation in under 2 minutes, enabling immediate real-time data collection without operational disruption.
  • Process Monitoring (41%): Pressure and Temperature sensors act as the workhorses of the field, replacing expensive wired instrumentation in remote wellheads and tank farms where trenching cable is cost-prohibitive.
  • The New Standard (2%): In December, we began shipping the industry’s first Wireless ATEX Zone 0 Differential Pressure Sensor. While it represents a small slice of 2025, it addresses a massive gap: monitoring filter clogging and tank levels in the most hazardous zones without conduit.

Global Validation: Designed for Harsh Environments  

The Voice of the Field  

The ability to integrate SENSAiO data into our existing SCADA without being forced into a proprietary cloud was the deciding factor. We own the network; SENSAiO provides the reliability.
– Lead System Integrator, Southeast Asia

Use Case Snapshots  

  • Critical Lineup Verification (Valve Sensors):A tank storage facility in Spain utilizes SENSAiO to digitize manual isolation protocols following water-purge operations. This interlock eliminates the risk of cross-contamination, ensuring no residual water enters jet-fuel distribution lines and safeguarding downstream aviation assets.
  • Remote Wellhead Monitoring (Pressure & Temp): An upstream operator in Indonesia replaced daily manual inspection rounds with SENSAiO wireless telemetry. By digitizing remote wellheads, the operator significantly reduced field logistics, employee risk exposure, and overall operating costs.
  • Filtration Integrity (Differential Pressure): In a refinery deployment, SENSAiO’s new Differential Pressure sensor provides continuous monitoring of filtration units. The system identifies early clogging trends before critical blockage occurs, enabling a shift to predictive maintenance while eliminating the need for manual gauge checks in hazardous zones.

The Ecosystem: Structuring for Scale  

  • 15 Global Resellers: We have moved closer to the client, establishing a network of certified partners who can deliver turn-key installation and integration.
  • Manufacturing Partnerships: We transitioned to a new assembly partner capable of high-volume production with automotive-grade quality control.
  • The Core Team: We streamlined our internal structure to a lean core team of 10, focused exclusively on R&D, Quality Assurance, and Global Operations.

The 2026 Outlook: Momentum & Maturity  

SENSAiO is ready for this expansion.


Ready to deploy? [Contact our Engineering Team] | [Download the 2026 Product Catalogs]