2CENSOR

2CENSOR Pty. Ltd. is a company founded in 2018 by Corey Vaughan that provides patented abrasive wear monitoring and predictive maintenance solutions for mineral processing assets. The business offers products like the 2C-Probe, 2C-Strip, and 2C-Mill to help operators minimise unplanned downtime and reduce maintenance overhead in harsh industrial environments. Their technology combines electronic telemetry with analysis software to deliver continuous, automated condition monitoring for equipment such as pipelines, mills, and cyclones.

The company's technology uses patented wear sensing probes and analysis software to enable real-time visibility into asset condition, allowing operators to know the known time to failure before a pipe bursts or mill liner fails. This approach helps minimise labour-intensive inspections and temporary patching while reducing the risk of environmental breaches from equipment failures. The system is designed specifically for the harshest environments where conventional monitoring often fails.

2CENSOR distributes its products globally through partners located in the Americas, Europe, Africa, and Asia-Pacific to support mineral processing operators on every continent. The company provides local engineering support combined with centralised data analytics to ensure consistent service from installation through to ongoing maintenance. This global reach allows them to customise solutions to suit various applications for remote industrial assets.

The business offers a free iOS onboarding app that enables fast configuration of monitoring devices through NFC and manual ID entry. This app is part of their broader strategy to integrate electronic telemetry with analysis software for predictive maintenance. Users can utilise the app to quickly onboard their sensors without needing complex manual setup processes.

Corey Vaughan founded 2CENSOR in 2018 after a critical incident at a coal mine site in Australia where a high-density polyethylene tailings pipeline wore through, causing an environmental incident and total failure costs exceeding AUD$1.1 million. This event prompted the development of a sensor capable of monitoring and predicting pipeline wear to proactively address maintenance challenges. The company was created to fill a gap in the market where existing options were either financially impractical or inaccurate.

The 2C-Strip sensor was specifically developed to eliminate the need of penetrating a wear plate or liner, offering a non-invasive monitoring solution. It is installed between wear plates, tiles, or liners to provide continuous data on internal wear. This design allows for easier integration compared to methods that require drilling or cutting into existing structures.

The 2C-Mill is the newest product released by the company, designed for real-time monitoring of mill liners in Sag / Ball Mills. It uses patented technology to provide data on the internal wear of these large industrial assets. This capability helps operators manage the condition of critical grinding equipment more effectively.

The 2C-Probe is the original patented wear sensor designed to solve a real-world industry problem by monitoring internal pipe wear. It has been further integrated into chutes, hoppers, and bins to provide comprehensive coverage for various mineral processing applications. This versatility makes it suitable for a wide range of internal asset monitoring needs.

The company's mission is to enhance mining sustainability through efficiency by delivering solutions that improve efficiency and productivity for remote industrial assets. They aim to close the loop on predictive maintenance by providing data analytics from installation through to ongoing maintenance. This holistic approach helps operators make informed decisions to prevent costly failures.

The business helps operators minimise downtime by replacing failing equipment during scheduled maintenance periods rather than during unplanned outages. This proactive strategy also reduces environmental risk by eliminating breaches that occur when equipment fails unexpectedly. Additionally, it lowers labour costs by minimising the need for frequent manual inspections and temporary fixes.

The company's website states that their technology can identify known time to failure before a pipe bursts, chute, hopper, or mill liner fails. This predictive capability allows operators to plan maintenance activities more effectively and avoid emergency repairs. By knowing when failure is imminent, companies can schedule interventions during planned shutdowns.

The 2CENSOR iOS onboarding app uses NFC technology to configure monitoring devices, streamlining the setup process for users. This feature ensures that the integration of new sensors is quick and user-friendly, reducing the time required for initial deployment. The app works alongside the centralised data analytics platform to provide a seamless experience from onboarding to ongoing monitoring.

The company's team includes a patent attorney, Alistair Smith, who is a principal at Davies Collison Cave, ensuring robust intellectual property protection for their patented probe technology. This legal backing supports the reliability and uniqueness of their wear sensing solutions in the market. The presence of experienced engineering and software development staff further strengthens their technical capabilities.

The company's contact information includes an email address, [email protected], which is used for inquiries about asset monitoring requirements. This channel allows potential customers to discuss customisation options and specific application needs directly with the business. The contact form on their website also facilitates communication for those who prefer to leave a message rather than call.

The official website of 2CENSOR is 2censor.com.