Bayer Antwerp: Scaling Predictive Maintenance Through a Decade-Long Partnership with I-care

When Periodic Monitoring Is No Longer Enough

Before evolving its approach, Bayer Antwerp relied on a traditional vibration monitoring program based on periodic measurement routes. These were typically performed every three months, and only when machines were running, leaving long periods without visibility on asset condition.

The same framework was applied across all assets, regardless of their criticality or operating context. In a complex environment combining batch processes, ATEX zones, and a wide variety of equipment, this lack of differentiation quickly showed its limits.

In practice, this created several challenges. Measurements often had to be performed outside working hours, while certain assets required additional follow-up that was difficult to organize within fixed schedules. As a result, maintaining a clear and up-to-date overview of asset health across departments was not always possible.

With such long intervals between measurements, potential issues could go undetected. This increased the risk of unexpected failures, slowed down reaction times, and exposed operations to downtime, production losses, and safety concerns.

As operational demands increased, it became clear that a more flexible and responsive way of working was needed, one that could provide continuous visibility, adapt to asset criticality, and support faster, more informed decision-making.

Building a Flexible Monitoring Strategy

To address these challenges, Bayer Antwerp and I-care implemented a more flexible monitoring approach, built around a hybrid strategy that combines manual measurements with wireless monitoring.

By combining advanced monitoring technologies with on-the-ground expertise, Bayer Antwerp ensures that insights are not only generated but clearly understood and acted upon. This balance between digital tools and human decision-making remains central to their approach to Predictive Maintenance solutions and Reliability Engineering practices. Rather than relying solely on automated systems, the focus is on enabling teams to make informed decisions based on accurate, timely data, strengthening both responsiveness and long-term reliability.

This close collaboration also creates a true partnership dynamic. As Mats Ribbens, Customer Success Manager at I-care, explains: “When working with Bayer, you’re seen as a colleague, not a supplier. That allows us to contribute to decision-making and provide better support when it matters most.”

Instead of applying a single method across all assets, the monitoring strategy is tailored to criticality, operating conditions, and safety constraints, such as ATEX environments. Critical equipment, especially where access is limited or conditions are more complex, is monitored with Wi-care™ wireless vibration sensors, while less critical assets are followed up through targeted manual vibration measurements. This approach focuses monitoring efforts where they bring the most value, while maintaining appropriate coverage across the asset base.

Scaling Predictive Maintenance with Subscription-Based Monitoring 

A key component of this approach is I-care’s Subscription model (Predictive Maintenance as a Service), which enables Bayer Antwerp to deploy wireless monitoring as a fully managed service. This includes the installation of sensors, data collection, expert vibration analysis, and access to I-care’s PdM AI-enhanced platform, while enabling Bayer teams to retain full control over maintenance decisions without requiring heavy upfront investment.

The deployment started with a Proof of Value in 2024, where wireless monitoring was introduced on selected assets to validate its impact under real operating conditions. The solution is now being progressively scaled across the site to monitor all critical assets by mid-2026. Today, 165 assets are already equipped with Wi-care sensors, out of approximately 700 assets on site.

Data collected from both manual inspections and wireless sensors is centralized and analyzed by I-care’s vibration specialists, enabling earlier detection of anomalies compared to periodic measurements. The results are shared through centralized PdM dashboards, giving Bayer’s team a clear and continuously updated view of asset condition while helping them prioritize maintenance actions and plan interventions more effectively.

By continuously adjusting the balance between online monitoring and manual follow-up, Bayer Antwerp can refine its approach over time. This flexibility allows the monitoring strategy to evolve alongside operational needs, ensuring that reliability efforts remain both effective and scalable.

Turning Continuous Data into Faster and Smarter Decisions

The shift to a hybrid monitoring strategy, supported by I-care’s Subscription model and Wi-care wireless sensors, has significantly improved how Bayer Antwerp manages its assets. What was once a process with limited visibility between periodic measurements has evolved into a system with more continuous insight and faster response capabilities.

With Wi-care sensors continuously collecting data and feeding the I-see platform, anomalies are now detected much earlier. Instead of waiting for the next measurement round, teams are alerted when deviations appear, giving them the time to assess the situation, prepare interventions, and decide on the appropriate course of action. This earlier visibility enables teams to assess situations sooner, prepare appropriate interventions, and make informed decisions, helping reduce the risk of unexpected failures, downtime, and production losses.

This increased visibility is reinforced by centralized dashboards within the I-see platform, providing a clear and up-to-date overview of asset health across the site. Maintenance teams can prioritize actions more effectively, make faster decisions, and take ownership of their assets with greater confidence.

Several real-life cases illustrate this impact. A sudden increase in vibration on a critical motor was detected early through wireless monitoring, allowing teams to anticipate the intervention, prepare spare parts in advance, and plan the replacement in a controlled manner, helping limit operational disruption. On cooling tower pumps, bearing issues were identified in time to prevent collateral damage. In another case, vibration data helped optimize the cleaning cycle of a centrifuge, improving process efficiency while maintaining reliability.

Beyond these individual examples, the broader impact is clear. As the deployment progresses, the number of monitored assets continues to increase, with 165 assets already equipped with wireless sensors out of approximately 700, and full coverage of critical assets targeted by mid-2026. Blind spots are being progressively reduced, and teams are moving away from reactive interventions toward a predictive way of working, supported by continuous data and expert vibration analysts from I-care.

Building on these results, Bayer has already started deploying this approach at additional sites, with further expansion planned. This confirms both the scalability of the solution and its role as a key enabler in strengthening Predictive Maintenance (PdM) and Reliability Engineering across the organization.