Digital monitoring enhances motor reliability at cement facility

~ WEG and Nuova Ites implement WEGSCAN solution to improve efficiency ~

Nuova Ites Srl, a leading European company specialised in repairing and overhauling electrical rotating machines, recently partnered with industrial equipment manufacturer, WEG to enhance operational monitoring of one of the key industrial motors of a cement facility. As part of their ongoing commitment to reliability and performance, Nuova Ites installed the WEGSCAN electric motor monitoring system, a cutting-edge solution developed by WEG to track motor performance and detect potential issues before they impact operations.

Nuova Ites, a specialist in repairing and overhauling electrical rotating machines across Europe, including more than 800 wind generators fully serviced in partnership with major operators such as Vestas, Enel and ERG Renew, identified the need for continuous motor monitoring in a high‑duty application. In this case, a 132 kW, 2‑poleWEG special series motor was coupled to an Atlas Copco compressor, forming a critical component of the client’s production process. Performance and reliability in this mixed‑equipment configuration were vital, but visibility into the motor’s ongoing condition was limited.

To address this, WEG supplied and installed a comprehensive monitoring solution consisting of the Gateway Cassia X2000 and the WEGSCAN 100 unit. Following a technical visit to the Nuova Ites workshop by WEG in late 2025, the equipment was ordered and delivered in early January 2026. The system was configured on‑site to meet the specific requirements of the application and integrated into both Nuova Ites’ and the cement factory’s monitoring processes.

The WEGSCAN system is designed to support real‑time monitoring of multiple operational parameters, including vibration signatures, temperature trends and other indicators of mechanical and electrical health. Its dual‑access capability enables engineers to check data from a standard PC interface or via smartphone, facilitating remote condition tracking and immediate visibility into performance.

Supporting the monitoring infrastructure is the Gateway Cassia X2000, which acts as the communication hub for the system. The gateway enables reliable wireless connectivity between the WEGSCAN device and the wider network, ensuring that operational data from the motor can be transmitted and accessed in real time. Designed for demanding conditions, the gateway operates within a wide temperature range of −40 to 65 °C, ensuring stable communication between sensors and monitoring systems in harsh operating environments.

By capturing continuous operating data, Nuova Ites can now identify early signs of abnormal behaviour and schedule maintenance proactively, helping to reduce unplanned downtime, optimise service interventions and improve overall energy efficiency. This level of insight is particularly valuable in environments where the costs of stoppages and reactive repairs are high.

“For Nuova Ites, the monitoring system has become an essential tool in its service portfolio, helping to integrate condition‑based maintenance into its standard workflow and offering clients enhanced reliability and lifecycle support”, said Fabrizio Arosio, motion drives and automation manager at WEG Italy.

“With the ability to monitor critical motors more closely, the company is better equipped to anticipate issues, streamline maintenance planning and provide data‑driven insights that add measurable value to asset performance and operational continuity.”

Digital monitoring technologies such as WEGSCAN also contribute to more sustainable industrial operations. By providing continuous insight into how motors perform in real operating conditions, operators can maintain equipment closer to its optimal efficiency point. In energy-intensive sectors such as cement production, improving the efficiency and lifespan of critical rotating equipment plays an important role in reducing overall resource consumption and supporting more sustainable plant operations.