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Less downtime, more performance from your data.

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From Sensor to Profit

Real-time Infrastructure

Thousands of sensors generate raw data, but no real answers. We connect every machine and every protocol, transforming tens of thousands of data points per second into actionable decisions.

Vibration · T-01
1.44mm/s
Temp · Bearing 4
68.2°C
Pressure · Main
143.0bar
Throughput
98.2%
LIVE TELEMETRY PIPELINE ONLINE · 24,800 MSG/S
[00:00:01] OT Ingestion via OPC UA / MQTT: Latency 3.8 ms — Streams synchronised.
[00:00:04] ML Inference Engine: No anomalies detected in turbine group B.
[00:00:07] Vibration Monitoring [T-01]: RMS 1.44 mm/s — High frequency spectrum nominal.
01

Any machine, any manufacturer

Via open industrial standards such as OPC UA, MQTT, Modbus TCP and Siemens S7, we connect every machine regardless of manufacturer, without creating proprietary silos.

02

Real-time AI & Early Warning

From the same telemetry data, our ML algorithms detect wear patterns and gradual performance degradation, often days before an unplanned outage occurs.

03

Full Control, No Lock-in

Because the platform is built on open standards, your team can operate and extend it independently, without becoming dependent on us or any other vendor.

Service Offering

4 Steps to Value

We accompany you from the first data audit to the optimised operation of your assets. To do so, we offer a modular portfolio, excellent expert knowledge and transparent processes.

01 · ANALYSIS 4 Weeks

Discovery

We analyse your existing data streams, identify critical bottlenecks and produce a comprehensive data and system audit of your infrastructure.

Results

  • ROI-driven business cases
  • Process and integration analysis of your heterogeneous infrastructure
  • Comprehensive technology roadmap
02 · FOUNDATION 6–10 Weeks

Foundation

We build an integrated data platform that brings your telemetry, ERP and machine data together in a flexible and secure data lakehouse.

Results

  • Data platform with KPIs across all assets
  • Harmonised data integration across your entire IT landscape
  • Robust OT/IT pipeline and governed data access
03 · DETECTION Ongoing

Downtime Prevention

A planned stop costs a fraction of an unplanned one: with our predictive maintenance we read the early warning signals, so that you schedule maintenance yourself instead of suffering a failure.

Results

  • Cheaper, more predictable maintenance windows through failure warnings
  • Fewer failures, less downtime
  • Equipment health management for fine-grained monitoring of your assets
04 · OPTIMISATION Ongoing

Throughput Optimization

Higher overall equipment effectiveness through AI-driven process parameter optimisation with minimal energy and resource usage.

Results

  • Better asset utilisation leads to optimal profitability
  • Lower energy input per unit produced
  • Traceable parameter decisions for your team

Evidence & Benchmarks

4 Sources · 2025–2026

See why investing in predictive maintenance and data architectures pays off today.

01 · Downtime Risk $10,000–$500,000 / h

36 hours unplanned downtime per year

  1. 25.000 $/h $0.90M
  2. 75.000 $/h $2.70M
  3. 150.000 $/h $5.40M
Highlighted bar: Median scenario at $75,000 per hour. Control-F calculation, 12 downtime events of 3 hours each, rates within the ABB study range.
Annual Downtime Risk at 36 Hours per Year
Hourly rateAnnual risk
25.000 $$0.90M
75.000 $$2.70M
150.000 $$5.40M

You know downtime is costly. You don't know your exact number.

79% of maintenance teams saw steady or rising unplanned downtime last year; 39% report rising costs per incident (previous year: 31%). 45% have no proactive modernisation plan whatsoever. Industry-wide cost estimates vary by a factor of 50 because most plants estimate rather than measure.

Sources: ABB, Modernization for Resilience global report, 14 Oct 2025, field research Sapio Research, n = 3,600 leaders. MaintainX, State of Industrial Maintenance Report 2026, May 2026, n = 2,234 maintenance and operations managers (USA and Canada). Figures in USD as published.
02 · OT/IT Maturity 34% real-time data

0 – 100% of 272 industrial operators

  1. Ambition
    1. 64 %
  2. Maturity
    1. 34 % −30 pts.
Highlighted bar: Maturity. Ambition = using or planning AI for predictive maintenance. Maturity = production systems stream data in real time. Hatched area marks the gap.
AI Ambition vs. Data Maturity, n = 272
CriteriaShare of respondents
Use or plan AI for predictive maintenance64 %
Stream production data in real time34 %
Cite data quality and availability as primary hurdle54 %
Cite legacy integration and data silos48 %
Cite trust, explainability and transparency43 %

The bottleneck is not the model. It is the data.

Asked about their greatest obstacle, 54% of industrial operators cite data quality and availability, 48% legacy integration and data silos, and 43% trust and explainability. Only 7% have anchored AI in core processes today. Gartner predicts that 60% of AI projects without an AI-ready data foundation will be abandoned by 2026.

Sources: HiveMQ / IIoT World, Industrial AI Readiness Report 2026, published 27 Jan 2026, field research 2025, n = 272 industry professionals (manufacturing, energy, transport). Gartner, Lack of AI-Ready Data Puts AI Projects at Risk, 26 Feb 2025, survey n = 248 data management leaders.
03 · Time-to-Value ROI < 6 Months

Of all maintenance teams

58 %

already use AI in live operations

Of these AI users

75 %

achieve measurable ROI in under six months

Highlighted bar: Return on investment. The two figures are based on different population baselines.
AI Adoption and Time-to-Value in Industrial Maintenance
CriteriaBaselineShare
Use AI in live productionAll teams58 %
Measurable ROI in < 6 MonthsAI users only75 %
Use or test AI agentsAll teams59 %
< 40% of time for planned workAll teamsapprox. 50%
59 % Use or test
AI agents
< 40% Time for planned work
in half of all teams

Predictive maintenance has left the pilot phase.

Half of all maintenance teams spend the majority of their working hours reacting rather than planning. That costs working hours across an unmonitored asset base before downtime costs even begin. The question is no longer whether predictive maintenance works, but whether your data foundation is ready for it.

Sources: MaintainX, State of Industrial Maintenance Report 2026, May 2026, n = 2,234 maintenance and operations managers (USA and Canada). The 75% figure refers to organisations already using AI.
04 · Energy & Compliance Audit due 11 Oct 2026

0 – 30 ct / kWh, non-household, 2nd half 2025

  1. Ireland
    1. 25.52
  2. Germany
    1. 22.64
  3. EU Avg
    1. 18.37
  4. Finland
    1. 7.48
Highlighted bar: Germany, 23% above the EU average and third highest price in the Union.
Industrial electricity prices (non-households), 2nd half 2025, cents per kWh
Marketct / kWhValue per saved GWh
Ireland25,52€255,200
Germany22,64€226,400
EU Average18,37€183,700
Finland7,48€74,800
11 Oct 2026 Energy audit
from 10 TJ / 2.78 GWh
11 Oct 2027 Certified EnMS
from 85 TJ / 23.6 GWh

In Germany, saving one gigawatt hour reduces costs by €226,400.

In Finland, the same saving corresponds to €74,800. Directive (EU) 2023/1791 requires enterprises consuming over 10 TJ annually to undergo energy audits, and over 85 TJ to implement a certified energy management system — regardless of company size. Both demand continuous, audit-proof consumption telemetry. This is a data engineering challenge before a regulatory one.

Sources: Eurostat, Industrial Electricity Prices H2 2025, published 8 May 2026. Directive (EU) 2023/1791 on energy efficiency, Art. 11; national transposition deadline 11 Oct 2025. Value per GWh calculated from Eurostat prices.

Security & Architecture

Enterprise Ready

We value Made in Germany and think European. That is why we work digitally sovereign, IT-secure and privacy-compliant, with our own servers, self-hosted LLMs and every state-of-the-art security technology.

IEC 62443 COMPLIANT

Non-invasive Edge Taps

Passive read-only access to telemetry data, like the on-board computer in a car: reading out yes, intervening in the controls never. Zero risk to active control loops or safety interlocks. Full air-gapped on-premise support.

OPEN LAKEHOUSE

Seamless Connections

Flexible, cost-efficient and reliable: as a Databricks partner, we combine the open data architecture of a data lake with the structure and transactional reliability of a data warehouse.

COMPLIANCE BY DESIGN

Digital Sovereignty

Legally sound procedures are no problem for us, because clean processes mean speed to us. For specialist questions on the AI Act or the Data Act we work with renowned law firms. And of course we protect your IP proactively.

FAQ

5 questions
How do we get started working with Control-F?
Successful engineering partnerships begin with understanding your operational architecture. We start every project with a focused discovery workshop to verify machine connectivity, align stakeholders, and define measurable ROI milestones before production rollout.
Can you integrate legacy assets and older field protocols?
Yes — legacy assets are the standard in industrial environments. Industrial machinery operates for decades while software evolves monthly. We integrate existing PLC infrastructures and historians non-invasively via OPC UA, Modbus, Siemens S7 and MQTT — without tampering with safety-critical PLC logic or causing production downtime.
How do you guarantee data security and sovereignty?
Your data never leaves the EU legal jurisdiction. We deploy inside your private data centre, on dedicated air-gapped infrastructure, or in certified EU sovereign clouds (STACKIT, Hetzner). End-to-end encryption (in transit and at rest), role-based access controls, and comprehensive audit trails are guaranteed.
How quickly can measurable results and ROI be expected?
Our structured 4-week discovery phase delivers a verified data roadmap and business case. Live edge telemetry pipelines are up within 14 days, and active machine learning models for anomaly detection and scrap reduction are fully operational within 8 to 10 weeks.
Do you offer long-term operational support and model retraining?
Yes. Continuous operation, drift monitoring, edge health tracking and model fine-tuning are an integral part of our partnership. We do not simply ship software — our engineers support your maintenance and operations teams throughout the entire asset lifecycle.