Guide · Old machines
How to monitor old machines without a PLC
Signals the sensor reads
Count pulse
Part or cycle
A sensor (for example, infrared) records each part or each machine cycle.
Limit switch
Movement
A mechanical contact marks the movement that repeats for each part.
Linear measurement
Length
Measures the length produced, for continuous processes such as cutting and extrusion.
Electrical activity
Current
Shows whether the machine is working or stopped. It does not count parts.
What to check before installing
The product type and the relation between cycle and quantity (how many parts per cycle).
The reading point, power supply and environmental conditions.
2.4 GHz Wi‑Fi coverage near the machine.
Checking the reading against an operation reference in the first days.
Who will record the stop reasons on the tablet.
Replace the machine or install a sensor?
Replace with a new machine
- High investment and lead time for purchase, delivery and installation.
- The team has to relearn how to operate.
- Without measuring first, you don’t know whether capacity was the problem.
Install a sensor
- Sensors ready within 7 days and installed in 1 day.
- The machine and its controls stay the same.
- You find out how much the current machine can still produce.
How Mestti installs
In the first conversation, we pick together the department and machines that matter most.
Sensors are ready within 7 days, configured for your machines.
Installation takes 1 day: sensor on the machine, 5 V USB-powered collector and the app on the tablet.
During a 1-week free trial, Mestti measures the real routine and you see the numbers.
If you don’t continue, we remove the sensors at no cost.
See the sensors’ technical sheet
Questions about old machines
Does any old machine work?
Age does not define compatibility. There has to be a reliable physical signal to read. We assess each machine before installing.
Do I have to stop the machine to install?
Installation is guided and respects the factory’s routine. The sensor is external and does not touch the controls.
What network does the factory need?
2.4 GHz Wi‑Fi (802.11 b/g/n) near the machines. If the connection drops, the sensor stores events and sends them later.
How is the sensor powered?
The collector runs on 5 V via USB, from a power supply. This does not mean a direct 110/220 V connection to the device.
Does the current sensor count parts?
No. Current shows whether the machine is working or stopped. To count parts, we use a part or cycle signal.
Before buying the next machine, measure the ones you have.
Leave your contact and we will schedule the demo at the best time for you.
Sensors ready within 7 days. Installed in 1 day.
Prefer to talk now? WhatsApp · (43) 99109-5035