Uninterrupted Monitoring
Unlike manual inspections, WedgeSense™ monitors 24/7 in real-time capturing thermal anomalies whenever they occur.
Stop Wedge Overheating Before It Stops Your Potline
WedgeSense™ – Advanced Busbar & Wedge Thermal Monitoring
WedgeSense™ detects busbar and wedge thermal runway with 2-48 hour advance warning. Prevent catastrophic potline shutdowns, avoid $1M+ incident costs, and maintain uninterrupted production with real-time thermal anomaly alerts.
A single wedge or busbar failure can cause over $1M in losses. WedgeSense™ helps prevent costly
potline shutdowns.
potline shutdowns.
Critical Problems Solved
Catastrophic Cost Avoidance
Prevent emergency shutdowns and the $1M+ costs that accompany them. Early intervention saves both money and operational stability.
Operational Continuity
Maintain steady potline operations by addressing thermal issues before they escape into production-stopping failures.
Predictable Failure Prevention
Wedge failures are preceded by thermal signatures. WedgeSense™ identifies these patterns 24-48 hours before failure, enabling planned maintenance.
Thermal Runaway Detection
Busbar and wedge temperatures can spike rapidly. WedgeSense™ monitors 950°C radiant heat and 600kA magnetic field environments to catch runaway conditions early.
2-Minute Installation
No shutdown required. WedgeSense™ installs in 2 minute on existing busbars, making rapid deployment to all potline sections feasible.
Transformative Impact
24-48 Hour Advance Warnings
Detect thermal anomalies before they become critical failures, enabling planned interventions instead of emergency shutdowns.
$1M+ Incident Prevention
Each prevented shutdown saves over $1 Million in lost production, emergency repairs, and operational disruption costs.
Zero Production Loss Installation
Deploy in 2 minutes without shutting down pots, making comprehensive coverage across all potlines economically.
24/7 Real-Time Monitoring
Continuous thermal surveillance catches anomalies whenever they occur, ensuring nothing is missed.
Predictive Maintenance Shift
Move from reactive firefighting to proactive thermal management, improving asset lifespan and reducing overall maintenance costs.
Operational Excellence
Achieve consistent potline performance with thermal data that drives continuous optimization and efficiency gains.
Core Capabilities
Uninterrupted Monitoring
Unlike manual inspections, WedgeSense™ monitors 24/7 in real-time capturing thermal anomalies whenever they occur.
Catastrophic Cost Avoidance
Prevent emergency shutdowns and the $1M+ costs that accompany them. Early intervention saves both money and operational stability.
Operational Continuity
Maintain steady potline operations by addressing thermal issues before they escape into production-stopping failures.
Predictable Failure Prevention
Wedge failures are preceded by thermal signatures. WedgeSense™ identifies these patterns 24-48 hours before failure, enabling planned maintenance.
Thermal Runaway Detection
Busbar and wedge temperatures can spike rapidly. WedgeSense™ monitors 950°C radiant heat and 600kA magnetic field environments to catch runaway conditions early.
2-Minute Installation
No shutdown required. WedgeSense™ installs in 2 minute on existing busbars, making rapid deployment to all potline sections feasible.
WedgeSense™ FAQs
A single unplanned potline shutdown from wedge/busbar failure costs over $1 Million in lost production, emergency repairs, downtime, and operational disruption.
WedgeSense™ detects thermal anomalies 24-48 hours before critical failure, providing sufficient time for planned maintenance and operational adjustments.
Installation takes just 2 minutes per sensor, with no shutdown required, making rapid deployment across the potline feasible.
Yes, WedgeSense™ is specifically designed to operate reliably in 600kA magnetic field environments, typical of potline busbar zones.
WedgeSense™ monitors 950°C radiant heat and accurately detects thermal anomalies across the full operating range of busbar/wedge zones.
Your Potline is Being Watched... By No One
WedgeSense changes that. Deploy across your potline today. Catch thermal runaway before it freezes your production.