EB Horsman & Son: How Condition Monitoring Solutions Help Avoid Hours of Unplanned Downtime
April 29, 2026
Condition Monitoring: How Banner’s Solutions Help Facilities Boost Uptime, Optimize Maintenance & Protect Their Most Valuable Equipment
Condition monitoring provides continuous, real‑time insights into machine performance by tracking vibration, temperature, current, and other critical parameters. Banner Engineering offers a complete ecosystem of sensors, gateways, and cloud analytics designed to help facilities detect failures early, plan maintenance proactively, and reduce unplanned downtime.
Banner offers targeted solutions for different asset types, making it easy to implement a tailored predictive maintenance program. Here’s how three of Banner’s most popular monitoring solutions help facilities boost uptime, optimize maintenance, and protect their most valuable equipment.
Why Condition Monitoring?
- Lower Maintenance Costs: By detecting issues early, maintenance teams can schedule targeted vibration analysis and corrective service at the right time, preventing minor problems from turning into major, high‑cost repairs.
- Greater Uptime: Continuous data insights support more accurate maintenance planning, helping facilities avoid unexpected shutdowns and keep critical equipment running reliably.
- Simple to Deploy: Wireless monitoring makes it easy to track assets in remote or hard‑to‑access areas without installing extensive wiring. Built‑in machine learning automatically establishes baselines and alert thresholds, reducing setup time and simplifying ongoing use.
Motor & Gearbox Monitoring: Protect Your Hardest‑Working Assets
Motors and gearboxes often sit at the heart of production lines—making them both high‑value and high‑risk. Banner’s Motor & Gearbox Monitoring Solution provides immediate insight into asset health by tracking vibration, temperature, and electrical load to detect early signs of bearing wear, imbalance, misalignment, or lubrication issues.
Customer Impact: Proven ROI & High‑Value Results
By installing Banner’s condition monitoring on their most critical motors and gearboxes, a global automotive OEM recovered 60+ hours of productive uptime and avoided over $3 million in unplanned downtime costs. The system’s fast installation and instant fault detection delivered immediate ROI, helping maintenance teams act earlier, schedule repairs smarter, and keep essential equipment running at peak performance.
How to Begin Monitoring Motors & Gearboxes
Sensors mount directly onto motors and gearboxes to capture two‑axis vibration data, while Banner’s VIBE‑IQ machine-learning engine automatically establishes baseline, warning, and alarm levels for predictive analysis.
These sensors also monitor temperature and combined with customizable thresholds tailored to each machine and environment, they trigger alerts whenever conditions exceed defined limits. For added insight, a current transformer can be installed on the AC supply to track amperage changes and generate notifications based on user‑set thresholds.
This is a simple starter list of the parts you’ll need, with options available for different sensor types, cable lengths, and connectivity preferences. Wireless setups make installation easier with fewer cables, while wired systems offer faster update rates for local monitoring. For guidance in selecting the right components for your application, the EB Horsman & Son team is there to help.
Air Filter Monitoring: Reduce Costs, Boost Efficiency & Improve Air Quality
Monitoring industrial air filters is one of the simplest and highest‑impact ways to improve operational efficiency. By tracking differential pressure across filter media, facilities gain real‑time insight into filter health—ensuring filters are replaced only when needed and preventing the hidden costs of poor filtration.
Customer Impact: Proven ROI & High‑Value Results
A paint‑booth customer doubled their filter life and saved over $100,000 annually by switching to condition‑based filter replacement. A modest $5,000 investment in monitoring delivered immediate ROI by reducing unnecessary filter changes, disposal fees, and scrap/rework.
How to Begin Monitoring Air Filter Health
By measuring the pressure drop across a filter (its differential pressure), you can determine how much airflow restriction is building up. A new filter has minimal resistance and therefore very low pressure drop. As the filter collects particulates during operation, airflow becomes more restricted, and the differential pressure rises accordingly, indicating the filter is nearing the point where it should be replaced.
This is a simple starter list of the parts you’ll need to begin monitoring. EB Horsman & Son also offers a wide range of sensor types, cable lengths, and connectivity options to fit your application. Wireless setups make installation easier with fewer cables, while wired systems provide faster update rates for local monitoring
Maximize Uptime with Hydraulic Power Unit Monitoring
Monitoring Hydraulic Power Units (HPUs) is an essential step in preventing unexpected maintenance issues, reducing operational costs, and keeping production running smoothly. By continuously tracking key parameters—including pressure, temperature, fluid levels, pump current draw, and motor/pump vibration—you can maintain stable system performance and act before problems escalate.
Customer Impact: Proven ROI & High‑Value Results
A customer added monitoring to six HPUs and found they were operating outside recommended temperature and pressure ranges. After correcting these issues, they expect to save over $30,000 in the first year through reduced maintenance and fewer replacement parts. A $5,000 investment delivered payback in under three months, with far greater ROI compared to their previous unmonitored systems.
How to Begin Monitoring Air Filter Health
By continuously monitoring system pressure, fluid temperature, current draw, and pump‑motor vibration, you gain a clear view of overall HPU performance—allowing you to prevent unexpected downtime and costly repairs. Changes in current draw and vibration can also indicate shifts in reservoir fluid levels, providing added insight into system health.
This is a simple starter list of the parts you’ll need to begin monitoring. EB Horsman & Son also offers a wide range of sensor types, cable lengths, and connectivity options to fit your application. Wireless setups make installation easier with fewer cables, while wired systems provide faster update rates for local monitoring.
How EB Horsman Can Support Your Condition Monitoring Needs
EB Horsman offers a full range of condition monitoring solutions to help you improve uptime, reduce maintenance costs, and keep your equipment running at peak performance. Whether you’re monitoring motors, gearboxes, air filters, hydraulic power units, or building a plant‑wide predictive maintenance strategy, their technical experts can help you choose the right solutions. Visit your local EB Horsman branch or contact them HERE
For more information on EB Horsman & Son solutions HERE
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