Kaeser uses EB for digital twin and predictive maintenance optimization

© Kaeser Kompressoren SE

Efficient even under pressure

Kaeser uses EB for digital twin and predictive maintenance optimization

Kaeser Kompressoren SE is one of the world‘s leading suppliers of compressed air products and services. Founded in 1919, the family business now has production facilities at two German sites and has around 5500 employees worldwide.

„Smart compressed air“

Kaeser Kompressoren SE „Smart compressed air“© Kaeser Kompressoren SE

Compressed air is just as important to industries as electricity. For even more reliability and higher design efficiency, Kaeser has developed a new digitization strategy, supported by AUCOTEC‘s data-driven software Engineering Base (EB). Under the banner „Smart compressed air,“ Kaeser offers networked compressors with intelligent control. Its digital twin allows the real-time monitoring of operating data, which is not only used for breakdown analysis and optimized maintenance intervals, but also for the continuous improvement of the product range and engineering.

The heart of the digital twin

„EB is the heart of our ‚smart engineering‘,“ explained Project Manager Patrick Dietz from Kaeser. „This is where the ‚digital twin‘ of the compressed air plant is created,“ he claimed. Its design, including control configuration and data transfer, is based on the analysis of the customer‘s situation. Its results, which are maintained in EB, can be traced over the entire project lifecycle.

Integrative database

All master data and documents accumulated over the service life of the plant are collected and processed in EB, including P&IDs or sketches. „EB is perfect for the integration of all technical information and changes, even from connected systems such as 3-D or automation,“ said the project manager. He claimed, „For the first time, everyone - including external partners - has access at all times to up-to-date data that is relevant for them, that is highly integrative!“ EB‘s database ensures consistency and completeness: information is only entered once and appears immediately in each representation of the edited object.

Efficient predicting

One of EB‘s highlights is its automated configuration of the data transfer from the control system to the predictive maintenance system (PdM). „Without EB, we would not have been able to offer PdM as such a good service,“ explained Falko Lameter, Head of IT at Kaeser. First, the PdM receives a list of all possible tags from EB. EB then „briefs“ the control system as to what is relevant for the PdM and how often and how precisely it should report the operating data to the PdM.


Kaeser is continuously expanding its use of EB together with AUCOTEC. „The decisive factor for our migration was EB‘s unique architecture with its central database core. Without them, we could not have realized our vision,“ concluded Falko Lameter.