XPLORE monitoring dashboard displayed on screen in an industrial compressor facility
Monitoring & Digital Services by Neuman & Esser

Convert Unplanned Downtime Into Planned Maintenance

The Industrial IoT platform for predictive maintenance and condition monitoring of industrial compressors. Hardware, cloud software, and OEM remote services from the engineers who designed your machines.

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More Than Just a Box

One Platform. Three Pillars.

XPLORE integrates dedicated IIoT hardware, a cloud-based SaaS platform, and a team of OEM compressor experts into a single, unified condition monitoring solution.

XPLORE Gateway industrial edge device with LTE antennas and Ethernet ports
Hardware

XPLORE Gateway

Industrial edge device for data acquisition and transfer straight from the PLC into the cloud. Plug-and-play installation via Ethernet with optional independent LTE connectivity.

XPLORE Platform dashboard showing machine fleet overview with availability metrics and alerts
Software

XPLORE Platform

Cloud-based SaaS platform with real-time dashboards, trend analysis, alarm management, and automated reporting. Accessible anywhere, secured to the latest cyber security standards.

Fleet Control Center: NEA engineers monitoring machine fleets on wall-mounted XPLORE dashboards
Service

Fleet Control Center

Dedicated 24/7 remote monitoring staffed by the OEM engineers who designed your compressors. Weekly health reports, event detection, root-cause diagnostics, and specific maintenance recommendations.

Platform Capabilities

Compressor Monitoring Built for Engineers Who Demand Precision

From 1 Hz PLC signals to 5,000 Hz high-frequency analytics, XPLORE captures every detail that matters.

01

Real-Time Monitoring & Trend Analysis

Acquisition of all machine data directly from the PLC with visualization for detailed analysis. Track historical trends, compare parameters across machines, and spot anomalies before they become failures.

  • Live data view with configurable time frames
  • Customizable alarm thresholds and notifications
  • Cross-machine parameter comparison
  • Wear progression tracking
XPLORE trend analysis view showing temperature data across multiple compressor stages over time
02

High-Frequency Data Analytics

Capture up to 5,000 Hz via edge technology for detailed pV-chart visualization. Event-based triggers automatically upload one-minute high-frequency recordings when thresholds are breached.

  • 4,800 Hz sample rate with cloud down-sampling
  • Automated threshold breach detection
  • Pressure curve analysis per rotation
  • Local ring buffer for raw data preservation
XPLORE high-frequency data analytics view showing pressure waveforms and vibration patterns captured at kHz sample rates
03

AI-Powered Health Scores

Deep learning models assess the actual condition of each compressor in real time. Health scores detect anomalies that fixed PLC alarm thresholds would miss, giving you early warning before performance degrades.

  • Color-coded health indicators (green / orange / red)
  • Autoregressive AI modeling of normal machine state
  • Validated through on-site testing with controlled faults
  • Independent of operating-case alarm values
XPLORE platform showing per-sensor AI health scores with color-coded trend lines detecting anomaly dips in real time
04

Make It Yours

XPLORE adapts to your operations, not the other way around. Define custom KPIs with a built-in formula builder, overlay live sensor data on your own process diagrams, and configure alarm thresholds and notifications to match your specific requirements.

  • Custom KPI formulas with freely selectable name, unit, and calculation
  • HMI view with live sensor data on uploaded process images
  • Configurable alarm thresholds and notification rules
  • Automated reporting with KPI visualization across periods
Product Portfolio

IIoT Monitoring Modules: Modular by Design

Choose the modules that match your monitoring needs. Each works with the XPLORE platform out of the box.

xGateway

Permanent PLC data module. Reads all signals at 1 Hz with plug-and-play Ethernet connection.

xRapid

High-frequency DAQ module. Captures kHz-range data with event-based cloud uploads.

xMobile

Portable ATEX-certified solution. Temporary HF monitoring with independent LTE connection.

xProtect

Diaphragm compressor safeguard. Oil peak pressure monitoring with automatic shutdown.

Beta

xConnect

Secure VPN remote access. Role-based machine access with portal management.

How It Works

From Data to Decision

From your compressor floor to clear insight, with OEM expertise at every stage.

1
On Site

Connect

XPLORE Gateway installs at the control cabinet. Plug-and-play Ethernet to PLC, independent LTE to cloud.

2
Cloud

Monitor

Data streams to the XPLORE Platform. Real-time dashboards, trend analysis, and automated alarm management.

3
Fleet Control Center

Analyze

OEM engineers review health data weekly. AI models detect anomalies. Root-cause analysis when needed.

4
Field Service

Act

Insights drive planned maintenance. Service technicians deploy with the right parts at the right time.

Cyber Security

Security by Design on All Levels

From the hardened Linux gateway to AWS cloud storage in Frankfurt, Germany, every layer of XPLORE is built with industrial-grade security.

  • Gateway hardening Minimal Linux OS with integrated firewall. Only approved outbound connections permitted, no inbound access from the internet.
  • Encryption All data encrypted in transit (HTTPS + WireGuard VPN) and at rest on AWS servers in EU-Central-1 (Frankfurt). Full German data residency.
  • Access control 2-factor authentication with federated identity management. Role-based permissions control visibility and configuration per user.
  • Air-gap option Hardware data diodes provide physical unidirectional data flow for environments requiring the highest separation level.
Optional: Data Diode
Physical unidirectional optical separation
Machine PLC
Compressors
Electrolyzers
XPLORE Gateway
Hardened Linux
Only approved
connections permitted
HTTPS
WireGuard
AWS Cloud
Frankfurt, Germany
AWS Cloud Storage
User Interface
Web-based access
& visualization
2-factor authentication with federated identity
Hardened Linux with integrated firewall
HTTPS, OpenVPN, and WireGuard tunnels
AWS Frankfurt with German data residency
Monitoring Levels

Modular. Configurable. Yours.

Three pre-configured levels to get started, or build your own configuration from individual modules. Every level includes the XPLORE Gateway hardware and platform access.

Basic

Platform Monitoring

  • XPLORE Gateway hardware
  • Platform & dashboard access
  • Real-time monitoring
  • Alarm management
  • Automated monthly reports
  • Expert-analyzed reports
  • High-frequency analytics
  • FCC remote monitoring
Get Started
Advanced

Platform + FCC Service

  • XPLORE Gateway hardware
  • Platform & dashboard access
  • Real-time monitoring
  • Alarm management
  • Automated monthly reports
  • Expert-analyzed reports
  • FCC remote monitoring
  • High-frequency analytics
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Professional

Full Suite

  • XPLORE Gateway hardware
  • Platform & dashboard access
  • Real-time monitoring
  • Alarm management
  • Automated monthly reports
  • Expert-analyzed reports
  • High-frequency analytics
  • FCC remote monitoring
Get Full Suite
Custom

Your Configuration

Every feature module can be added individually. Pick exactly the capabilities your operations require, from a single machine to an entire fleet.

  • Mix and match modules
  • Scale per machine
  • Application-specific add-ons
Talk to Us
Trusted by Industry Leaders

Proven in Critical Operations

Leading companies in hydrogen production, petrochemistry, and industrial gas processing rely on XPLORE for compressor condition monitoring and predictive maintenance across their machine fleets.

Hydrogen Production

Multi-site fleet monitoring across European electrolyzer and compressor installations

Petrochemistry

High-frequency vibration analytics for reciprocating compressors in continuous chemical processing

Industrial Gas

Fleet Control Center remote monitoring with OEM-grade diagnostics across distributed gas processing sites

190+
Years of compressor expertise
1,500+
Employees worldwide
24/7
Remote monitoring capability
See It in Action

XPLORE Platform Demo

Watch how we turn raw machine data into clear insight, from real-time dashboards and trend analysis to AI health scores and Fleet Control Center alerts.

NEA XPLORE Platform Demo - click to play
Get Started

Request a Live Demo

Our team will walk you through real monitoring data and show you how XPLORE fits your machine fleet.

Or reach us directly at support@neaxplore.com

FAQ

Questions About XPLORE

What is predictive maintenance for compressors?

XPLORE replaces fixed maintenance schedules with data-driven decisions. Instead of waiting for breakdowns or servicing on a calendar, the platform continuously monitors machine health and alerts your team before performance degrades.

  • Real-time sensor data detects early signs of degradation
  • AI analytics flag issues that fixed alarm thresholds miss
  • Maintenance moves to scheduled downtime, not emergency stops
What data does the XPLORE Gateway collect?

The Gateway reads all available PLC signals via a plug-and-play Ethernet connection, no changes to your existing network required.

  • Standard: 1 Hz PLC data (temperatures, pressures, states)
  • xRapid module: up to 5,000 Hz for pressure curves and vibration
  • Connectivity: independent LTE or integration into your existing company network
Is XPLORE compatible with non-NEA compressors?

Yes. XPLORE works with any industrial compressor that has a PLC with an Ethernet interface, regardless of manufacturer.

  • Monitoring, trending, and alarms work with any OEM
  • The Fleet Control Center's expert analysis is optimized for NEA-produced machines
How long does installation take?

Under one hour per machine. The Gateway connects via a single Ethernet cable to the PLC and communicates to the cloud via LTE or your company network.

  • No IT network integration or firewall changes
  • No software installation on your systems
  • Most customers are live within one business day
How does XPLORE handle data security?

Every layer is built with industrial-grade security and full German data residency.

  • Encryption: HTTPS + WireGuard VPN in transit, AES at rest
  • Hosting: AWS Frankfurt (EU-Central-1) exclusively
  • Access: 2-factor authentication with role-based permissions
  • Air-gap option: hardware data diodes for physical separation
  • XPLORE processes machine data only, no personal data
What industries does XPLORE support?

XPLORE is built for safety-critical, continuous-operation environments where unplanned compressor downtime carries high financial risk.

  • Hydrogen production and electrolysis
  • Petrochemical processing
  • Industrial gas production
  • General manufacturing
What is an AI Health Score?

A per-sensor indicator generated by deep learning models that learn each compressor's normal operating behavior.

  • Autoregressive modeling detects subtle deviations across multiple sensors
  • Color-coded: green (healthy), orange (watch), red (act now)
  • Validated through on-site testing with controlled faults
  • Early warning days or weeks before traditional alarms trigger
What does the Fleet Control Center include?

24/7 remote monitoring by the NEUMAN & ESSER OEM engineers who designed your compressors.

  • Weekly health analysis reports
  • Real-time event detection and alerting
  • Root-cause diagnostics with access to design data and service history
  • Prioritized maintenance recommendations