IPEL Adopts Predictive Maintenance Technology and Saves Nearly R$500,000

Brazilian tissue producer IPEL has implemented a predictive maintenance system powered by artificial intelligence to improve operational efficiency and prevent unexpected equipment failures at its industrial plant. The initiative is part of the company’s broader strategy to strengthen innovation and modernize production processes.

The system, deployed in 2025, uses the Tractian platform, which relies on smart sensors to continuously monitor critical industrial assets. These sensors measure parameters such as vibration, temperature, rotation and operating time, transmitting data to the cloud every ten minutes via 3G/4G networks for real-time analysis.

According to the company, the technology has already enabled maintenance teams to detect early signs of failure in key components, preventing breakdowns and generating savings of nearly R$500,000 that could have resulted from unexpected equipment damage and production interruptions.

A major advantage of the system is its embedded artificial intelligence, which can track more than 70 potential failure modes. By combining machine learning with operational data and feedback from maintenance teams, the platform continuously improves its predictive accuracy and supports more efficient maintenance planning.

The predictive maintenance project complements other initiatives implemented by IPEL to enhance operational efficiency and sustainability, including an energy-efficiency program developed with Celesc, which delivers annual savings of around R$650,000, and improvements to the plant’s biological treatment system.

Company executives say the initiatives mark a shift toward a more data-driven industrial model, aligning IPEL with Industry 4.0 trends and reinforcing its competitiveness in the tissue market.

Founded more than 40 years ago and headquartered in Indaial, Santa Catarina, IPEL produces tissue products such as toilet paper, paper towels and napkins, supplying both retail and professional markets with monthly production exceeding 7,000 tonnes.