Every machine, every minute, accounted for.
IoTMon clips onto the knitting machines you already run, whatever the brand or age. Run time, RPM, overspeed, stops, repair times, vibration, energy and fabric defects, live on your phone, so your shift report shows what really happened.
- Live in 10 working days
- No PLC wiring
- No production stop
Demo floor: 32 circular knitting machines
Simulated data. Select a machine.
- Running
- Below standard speed
- Stopped
- Live RPM
- 27rated 26
- Efficiency
- 63%
- Vibration
- 4.5mm/s
- Output
- 93kg
Your register says 86%. The machine says otherwise.
Counters tell you a machine stopped. They never tell you why, who fixed it, or how long it took. Short stops for a yarn break, a needle change or a missing operator never reach the register. IoTMon logs every stop with its reason and repair time, so you fix the biggest loss first.
Where the time went
- Running343 min
- No operator51 min
- Yarn breaks49 min
- Doffing25 min
- Needle change12 min
Repair log, longest first
| Time | Reason | Attended by | Repair |
|---|---|---|---|
| 08:50 | No operator | None | 35 min |
| 12:05 | Doffing | Operator | 25 min |
| 13:32 | No operator | None | 16 min |
| 11:00 | Needle change | Technician, waited 7 min | 12 min |
Example: one machine, one 8-hour shift. A pilot measures your own baseline before we make any claim.
Faster isn't free
To hit the shift target early, karigars push machines above rated RPM, then rest while the machine stands idle. The target is met, so it looks like good production. Meanwhile needles, cams, belts and bearings wear faster and the spares bill grows. Until now nobody could prove it. IoTMon records it, minute by minute.
74 minutes over rated speed this shift. Target hit at 20:10, idle since.
- 01
Recorded
Minutes above rated RPM for every machine, shift and operator, plus the idle time after the target is hit.
- 02
Alerted
The shift in-charge gets a push notification and a WhatsApp message the moment a machine runs over its limit.
- 03
Costed
Overspeed history sits next to each machine's breakdowns, vibration trend and spare-part use, so you can see what speeding costs you.
- 04
Fixed
Set a speed policy per design and pay incentives on steady, in-spec output instead of an early finish.
One clip-on kit, seven signals
Each machine gets a small node with a current clamp, a speed sensor and a vibration sensor. No PLC access, no rewiring of your controls. It works the same on a 1998 machine and a 2024 one.
- Current clamp
- Speed sensor
- Vibration sensor
Run time
Running, idle or stopped, every minute, read from motor current.
RPM
Cylinder speed and revolutions per roll.
Overspeed
Minutes above rated RPM per machine, shift and operator.
Stops and repairs
Every stop with its reason, who attended and how long it took.
Vibration
Bearing and cam wear trends, flagged before failure.
Energy
kWh per machine and per kg of fabric.
Fabric defects
Holes, needle lines and drop stitches, with IoTMon Vision.
Cameras that stop the machine before the roll is ruined
IoTMon Vision checks fabric as it is knitted and stops the machine when a defect repeats, so you lose a few centimetres instead of a whole roll. On your existing CCTV, it tracks idle machines, unattended zones and safety.
Illustration of defect classes the vision model labels on fabric.
| Task | Inline camera | Your CCTV |
|---|---|---|
| Holes, needle lines, drop stitches, lycra misses | ||
| Auto-stop on a repeating defect | ||
| Defect map written to the roll's QR record | ||
| Unattended machines and idle zones | Not needed | |
| PPE and safety events | Not needed |
Ordinary CCTV can't resolve stitch-level defects. Fabric inspection needs a dedicated camera and light at the knitting point, and we'll tell you that before you buy.
Models run on an edge box in your mill. Video stays on site, only events go to the dashboard. Each model is trained on your own fabrics during the pilot.
Scan a roll, see its whole story
When a roll is doffed, IoTMon Trace prints a QR label automatically. Your QA team, the dyeing house or a buyer's auditor can scan it with a phone and see where the roll came from and what happened to it.
- Roll and lot number
- Machine, gauge and diameter
- Design, GSM and weight
- Yarn count, lot and supplier
- Shift, operator, start and end time
- Defects found by Vision
- Dyeing and finishing stages
- Buyer and order number
Answers buyer audits in minutes and lays the data groundwork for the EU's coming Digital Product Passport for textiles.
- Machine
- M-14, 30" 24G
- Design
- Single jersey lycra
- GSM
- 180
- Weight
- 24.6 kg
- Yarn
- 30/1 CVC, lot Y-7781
- Shift
- B, 14:00 to 22:00
- Knitted
- 10 Nov, 15:12 to 19:40
- Order
- PO-55210
- Next stage
- Dyeing, batch D-309
Your whole floor, live, wherever you are
IoTMon Pulse runs on the web, on the floor TV and in our mobile app. In Karachi, Dubai or Milan, you see the same live floor as your shift in-charge. And it does more than show numbers: it tells you what to do next.
Live from anywhere
Every machine's state, RPM and output, updated in seconds, in any browser.
Mobile app for Android and iOS
Floor map, machine history, shift reports and roll lookup in your pocket.
Push and WhatsApp alerts
Long stops, overspeed, vibration, overheating and repeat defects, sent to the right person by role.
Anomaly detection
Each machine learns its own normal speed, vibration and power draw, and flags anything unusual.
AI suggestions and forecasts
Next actions ranked by rupee impact, likely failures in the next 14 days, and orders at risk.
Maintenance log
Every repair timed from stop to restart, per fault, machine and technician.
- IoTMonnow
M-13 stopped 18 min: needle change. No technician has checked in.
- IoTMon4 min ago
M-07 running at 31 RPM, rated 26. Shift B, karigar Asif.
- IoTMon22 min ago
M-18 vibration 5.6 mm/s, above the 4.5 limit. Bearing check suggested.
- IoTMon1 h ago
Shift A closed: 2,410 kg, 81.2% efficiency, 3 points above last week.
Replace M-18 bearing during Sunday's doff
Vibration rose 40% in 10 days, matching the pattern before past bearing failures.
Avoids about 9 h of unplanned downtimeCheck the yarn lot on M-21 to M-24
Shift B loses 52 minutes a day to yarn breaks on these four machines, all fed from lot Y-7790.
About 140 kg a week recoveredCap speed on M-07 and M-11 at 26 RPM
Both ran over rated speed 61% of last week and needed needles twice as often as the others.
Lower needle and cam spendOrder PO-55210 is at risk
At today's rate it finishes 2 days late. Moving it to M-02 and M-03 brings it back on time.
Ship date protected
Example screens with illustrative data.
Cloud or on-premise. Your data, your choice.
Same sensors, same dashboard, same app. You decide where the data lives.
IoTMon Cloud
You don't have to worry about anything. We host, run, back up and update it all.
- No server to buy or manage
- Live floor on your phone from anywhere in the world
- Push and WhatsApp alerts built in
- AI suggestions and forecasts improve automatically
- Daily backups, security patches and updates handled by us
- Included in every subscription
On-premise
Your data never leaves the factory. You provide the server, we install, secure and support it.
- All data stored on your own server, inside your network
- Works without internet, remote viewing through your own VPN
- Dashboard, app and AI suggestions run locally
- Quarterly updates, installed with your IT team's approval
- Same per-machine subscription, plus a one-time PKR 75,000 setup
Server you provide (up to 300 machines): 8-core CPU, 32 GB RAM, 2 × 1 TB SSD in RAID 1, Ubuntu Server 24.04 LTS, an online UPS. Add a 16 GB NVIDIA GPU if Vision runs on it too. We size larger floors during the site survey.
What a few points of efficiency are worth
Move the sliders to match your floor. These are planning estimates. The pilot replaces them with your measured numbers.
Volume discount of 10% applied.
- Extra output per month
- 23,400 kg
- Value of extra output
- PKR 2,106,000
- IoTMon subscription
- PKR 112,500
- One-time hardware and gateways
- PKR 1,080,000
- Hardware pays back in
- Under a month
Based on 26 working days a month, volume discounts of 10% at 100+ machines and 15% at 300+, and one gateway per 60 machines. Excludes avoided breakdowns, fewer second-grade rolls and energy savings.
How the 30-day pilot works
Ten machines, thirty days, one clear answer in rupees. The pilot fee is fully credited to your rollout if you sign within 30 days.
- 1Day 1
Site survey
We record each machine's brand, gauge and motor, check power and Wi-Fi, and take your current efficiency figures.
- 2Days 2 to 4
Install during doffs
30 to 45 minutes per machine with two technicians. No PLC wiring and no stopped production.
- 3Days 5 to 11
Silent baseline
Seven days of measuring with alerts off, so you see your true starting point.
- 4Days 12 to 30
Act and review
Alerts, floor TV and stop-reason pads go live. We finish with a loss report in rupees and a rollout plan.
Pricing in rupees, per machine
Launch pricing for the first 12 months: a one-time hardware fee and a monthly subscription. Prices exclude sales tax.
Pilot
Prove it on your floor
- Run/stop, RPM, efficiency
- Overspeed tracking and alerts
- Stop reasons, repair times, shift reports
- Mobile app, push and WhatsApp alerts
- Anomaly detection, AI suggestions, forecasts
- Vibration and predictive maintenance
- Energy, kWh per kg
- API and ERP export
- Fabric defect detection and auto-stop
Sense Essential
See every stop
- Run/stop, RPM, efficiency
- Overspeed tracking and alerts
- Stop reasons, repair times, shift reports
- Mobile app, push and WhatsApp alerts
- Anomaly detection, AI suggestions, forecasts
- Vibration and predictive maintenance
- Energy, kWh per kg
- API and ERP export
- Fabric defect detection and auto-stop
Sense Pro
Catch faults early
- Run/stop, RPM, efficiency
- Overspeed tracking and alerts
- Stop reasons, repair times, shift reports
- Mobile app, push and WhatsApp alerts
- Anomaly detection, AI suggestions, forecasts
- Vibration and predictive maintenance
- Energy, kWh per kg
- API and ERP export
- Fabric defect detection and auto-stop
Vision Inline
Stop defects at source
- SenseRun/stop, RPM, efficiency
- SenseOverspeed tracking and alerts
- SenseStop reasons, repair times, shift reports
- Mobile app, push and WhatsApp alerts
- Anomaly detection, AI suggestions, forecasts
- Vibration and predictive maintenance
- Energy, kWh per kg
- API and ERP export
- Fabric defect detection and auto-stop
Trace, QR lot records
PKR 12,500 per site per month. Label printer supplied at cost.
Vision on your CCTV
PKR 1,500 per camera per month. Edge box PKR 75,000 per site.
On-premise hosting
Same per-machine subscription, plus PKR 75,000 one-time server setup. You provide the server.
No upfront hardware
Rent the Sense kit for PKR 450 per machine per month on a 24-month term.
Built for textile, ready for any machine with a motor
We started where Pakistan's exports are made. Every node is the same hardware, so a new machine type is new calibration, not a new product.
Circular knitting
Available nowSingle jersey, rib, interlock, fleece. RPM, revolutions, stops, defects.
Weaving looms
Pilot on requestAir-jet, rapier and projectile. Picks per minute, warp and weft stops.
Spinning
Pilot on requestRing frames and autoconers. Spindle speed, breaks, doff timing.
Dyeing and finishing
Pilot on requestJets, stenters, compactors. Temperature, run time, energy, batch records.
Garment lines
PlannedSewing and cutting machines. Run time per operator, line balancing.
Beyond textile
PlannedPackaging, plastics injection, food and pharma lines.
Questions mill owners ask us
No. The node reads motor current, cylinder speed and vibration from outside, and takes the stop signal from the machine's existing stop-motion lamp or relay. Your controls and warranty are untouched.
Book a 30-day pilot
Tell us about your floor. We'll call within one working day to arrange a site survey.
- Emailinfo@iotmon.com
- OfficeKarachi, Pakistan. Field visits to Faisalabad and Lahore.
- CompanyIoTMon is a subsidiary of Nedian Technologies