Smart asset monitoring for zinc production

Detect hard-to-reach equipment failures before they stop production with SAM4

Avoid exposing sensors to acid, heat, and moving parts. Monitor directly from the motor control cabinet, with no on-machine sensors required.

Trusted by leading metals and mining companies

What is SAM4?

SAM4 is a condition monitoring system for industrial motors and rotating equipment. It uses Electrical Signature Analysis (ESA) to monitor the condition and performance of assets from inside the motor control cabinet (MCC). Our ESA algorithms use electrical signals from assets to identify developing electrical and mechanical faults weeks before they lead to failure. Because it operates from the MCC, SAM4 can monitor assets in hard-to-reach, hazardous, submerged, or extreme-temperature locations – no need to install sensors on the equipment itself.

How it works: From electrical signals to failure prediction

Measure electrical signals

Voltage and current signals from the drivetrain are sampled at 20–64 kHz from the safety of the motor control cabinet.

Develop spectra for drivetrains

SAM4’s ESA algorithms convert electrical signals into frequency spectra which can be used to identify patterns of behavior in a drivetrain.

Detect abnormal behavior

Developing mechanical or electrical faults, such as belt misalignment or pump cavitation, show up as visible spikes in the spectrum.

Predict failure well in advance

We track the evolution of these spikes, anticipating failure weeks to months in advance and giving you time to schedule targeted maintenance.

How SAM4 helps zinc plants to monitor hard-to-reach equipment

Continuous zinc lines run through acid, heat and moving material – where on-machine sensors fail or can’t be installed. SAM4 monitors directly from the motor control cabinet (MCC) to turn those blind spots into early, actionable alerts that keep throughput steady.

Leaching and purification

Clogging and cavitation in mixers and pumps trigger off-spec batches and sudden stops. From the cabinet, SAM4 flags load and imbalance changes early and sends analyst-reviewed actions – without the need for sensors near corrosive operation.

Electrolysis

SAM4 monitors pumps and blowers from the motor control cabinet, spotting faults early so zinc plating is done evenly and emergency repairs are avoided.

Conveyors and coil handling

Detect gearbox and motor overloads, belt misalignment and sticky build-up by spotting fault patterns from the motor control cabinet, with clear recommendations to keep conveyors moving.

The impact of Samotics across industries

ROI in just 8 months

On average, customers recover their investment in 8 months (see case studies).

96% detection accuracy

Our world-leading detection accuracy identifies 96 out of 100 critical failures across industries.

30% longer machine lifetime

Equipment lasts longer with fewer emergency repairs from escalating faults.

Up to 25% lower energy use

Detects hidden inefficiencies inside industrial equipment so energy isn’t wasted on friction, imbalance or wear.

ROI in just 8 months

On average, customers recover their investment in 8 months (see case studies).

96% detection accuracy

Our world-leading detection accuracy identifies 96 out of 100 critical failures across industries.

30% longer machine lifetime

Equipment lasts longer with fewer emergency repairs from escalating faults.

Up to 25% lower energy use

Detects hidden inefficiencies inside motors and pumps so energy isn’t wasted on friction, imbalance or wear.

ROI in just 8 months

On average, customers recover their investment in 8 months (see case studies).

96% detection accuracy

Our world-leading detection accuracy identifies 96 out of 100 critical failures across industries.

30% longer machine lifetime

Equipment lasts longer with fewer emergency repairs from escalating faults.

Up to 25% lower energy use

Detects hidden inefficiencies inside motors and pumps so energy isn’t wasted on friction, imbalance or wear.

See how zinc smelter Nyrstar got 800% ROI in 11 months with Samotics

In this video, zinc smelter Nyrstar shares how condition monitoring using Samotics’ smart asset monitoring solution, SAM4, resulted in 7 developing asset faults getting flagged early. This helped Nyrstar avoid over €1M in costs, get ~800% ROI in 11 months, and move from midnight breakdowns and emergency fixes to a structured, proactive approach to maintenance.

Smart asset monitoring

Detect developing faults early and take the right action

Early fault alerts

Catch faults before they escalate

Receive notifications in your inbox with the level of urgency, which asset is affected and what you can do to solve it.

Incident insights

Get clear insight into the detected fault

Spot developing failures early with clear signals of root cause – so you can act before issues become critical.

Actionable recommendations

Know what next steps to take

Alerts come with clear, data-driven recommendations, helping you pick the right team with the right tools, and avoid unnecessary trips.

Smarter and more actionable alerts

Stay ahead with early warnings

Know which issues are critical - and which can wait

As issues develop, alerts escalate by change of color, giving you time to take action before downtime occurs.

Turn alerts into work orders in seconds

Improve efficiency by enabling teams to take immediate action from email notifications.

Keep teams aligned with real-time comments

Add and view comments via incident emails to ensure everyone stays informed and actions are coordinated.

Testimonials

Delivering results across industries

We’re a forward-looking company, always looking for ways to improve the safety, reliability, and sustainability of our production processes. Samotics has proven itself a valuable partner there. Thanks to SAM4, we can monitor assets that would otherwise remain unreachable.

Andy Roegis

Industrial Digitalization Manager

ArcelorMittal

The real-time information SAM4 provided allowed us to schedule maintenance before breakdowns occurred. At first I was a bit skeptical about SAM4’s ability to detect failures by analyzing electrical waveforms, but the results speak for themselves: It just works.

Marcel den Blanken

Baggage Service Manager

Schiphol Airport

This technology is ideal for borehole pumps. They can be 150-180 meters below ground, so having to fit a monitor to the pump would be very tricky. Every time there is an issue with it, you would need a crane on site as well as a group of technicians to lift the pump. Having SAM4 in the MCC is much easier to set up and maintain.

James Nobbs

Groundwater Engineering Manager, Water Services

Anglian Water

SAM4 delivers clear and actionable insights that enable our teams to make swift, informed decisions. This newfound visibility empowers us to make informed, proactive decisions that significantly improve our maintenance efficiency, ensuring we have the right personnel in the right locations at the right time for a successful first-time fix.