8 Technology trends for predictive maintenance 2025

The power of technology lies in its ability to transform the way we do things. In our case, it enables us to offer increasingly advanced solutions aimed at increasing reliability, reducing operating costs and optimizing industrial processes.

This 2025 comes loaded with technological advances. Here are eight trends that will shape the future of industrial maintenance:

1. Artificial Intelligence (AI)

Artificial intelligence enables machines to learn, reason and make decisions. It has the ability to process large volumes of data in real time and detect patterns that humans could not easily identify. Thanks to machine learning algorithms, platforms can foresee failures before they occur.

For example, neural networks analyze the vibrations of an engine and determine abnormal deviations, enabling early and accurate interventions.

2. IoT (Internet of Things)

The Internet of Things is an interconnection of devices that collect and share data in real time over the Internet. It enables intelligent sensors to be connected to critical equipment, providing constant data on variables such as temperature, pressure and speed. This connectivity transforms operations by providing real-time remote monitoring.

For example, sensors installed on a wind turbine collect data that is sent to a cloud platform, where it is processed to predict the wear and tear of key components.

3. Drones for inspection and monitoring

Drones have been a revolutionary solution for inspection in hard-to-reach locations, such as power towers, refineries or solar plants. Equipped with thermal cameras and advanced sensors, they can identify hot spots, cracks or structural failures without exposing personnel to unnecessary risk.

For example, in a power plant, a drone can fly over and detect transformer overheating in real time.

To offer our aerial inspection service, we use state-of-the-art drones equipped with a high-performance thermographic camera. This equipment allows us to capture images and record high quality videos, facilitating the detection of possible faults or critical failures.

We provide solutions to various industries through aerial inspection services in difficult to access infrastructures, such as:

Oil & Gas: refineries, pipelines and offshore platforms.
Mining: open pit operations.
Maritime sector: transportation, cargo, fishing and passenger vessels.
Construction: monitoring and supervision.
Electricity generation: wind farms, photovoltaic, solar thermal and thermal power plants.

Learn more about our aerial inspection service here.

4. Digital twins

A digital twin is a virtual representation of a physical asset that allows its behavior under different conditions to be simulated. In maintenance, digital twins provide accurate simulations that help to predict failures and optimize performance.

For example, a petrochemical plant can use a digital twin to simulate the impact of operational changes on its critical assets to see what kind of failures and damage may occur. It is an ideal tool for simulating situations.

5. Cloud platforms and Big Data analysis

Cloud-based platforms have democratized access to advanced analytics tools, allowing companies to store and process large volumes of data securely and efficiently. With Big Data, data collected from different sources is analyzed to identify trends and predict failures.

For example, continuous monitoring sensors that monitor the condition of 20/7 machinery generate data that, when processed in the cloud, optimize maintenance plans based on actual asset usage.

We are joining this digital revolution with our advanced operational management and asset health system that aims to monitor, in real time, the status of the plants.

What can our software do for your plant?

Follow-up and planning of maintenance plan tasks (preventive and predictive)
Predictive equipment reporting and monitoring
Supervision and organization of daily tasks that are not part of the maintenance plan (corrective, corrective-different).
Obtaining graphs to support decision making according to the detected failure.
Real-time detection and notification of anomalies en route
Service request management and workload planning
Equipment background
And much more

6. Condition Based Maintenance (CBM)

Condition-based maintenance uses sensors and algorithms to monitor the actual condition of equipment, allowing repairs to be scheduled before critical failures occur. This strategy helps reduce costs and downtime by intervening only when necessary.

For example, a CBM system can measure the electrical resistance of a motor in real time and schedule maintenance before the insulation fails.

7. Virtual Reality (VR) and Augmented Reality (AR)

These technologies are revolutionizing training and technical support. Virtual reality allows complex scenarios to be simulated to train technicians without risk, while augmented reality provides in-field assistance through devices that overlay digital information on real equipment.

For example, a technician can use AR glasses to view interactive diagrams while performing an adjustment on a machine.

8. 3D scanners

3D scanners allow the creation of accurate models of equipment and components, facilitating wear and deformation analysis. They are very useful for reverse engineering and part design. In predictive maintenance, this technology is especially useful for detecting irregularities in critical parts such as turbines, rotors or gears.

For example, a 3D scanner can identify microcracks in a rotor before they cause catastrophic failure.

The future of predictive maintenance is marked by these innovative technologies that improve efficiency and drive the digitization and reliability of industrial processes. Adopting them is not only a competitive advantage, but a necessity to ensure the sustainability of operations in an increasingly demanding environment.

At DSP Analytic, we are at the forefront of these trends, offering technological solutions tailored to the needs of each client. We invite you to explore our portfolio of services and discover how we can help you optimize your operations.

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