Customer Story: Hastings Energy Control, Inc.
Energy Saving Smart
Industrial Air Filtration
Immediate Impact
Customer Buy-in
Customers that will include IVEC Command with Control product purchases
Revenue Growth
Revenue growth over 18 Months related to IVEC Command
Time Reduction
Reduction in time commissioning a new customer with Exosite compared to a legacy connected solution.
A Leader in Industrial Air Filtration
Hastings Air Energy Control manufactures and services advanced industrial ventilation, vehicle exhaust removal, air filtration, and energy-saving control systems that improve air quality in industrial environments. Their innovative, efficient, and sustainable solutions are built to exceed industry standards and create a safer, healthier workplace.
Applications for Hasting's products include:
- Ambient Fume, Dust, Odor, Smoke
- Dust Collections (including Wood, Cement, Blending, Grinding)
- Welding Smoke & Fume
- Vehicle Exhaust Removal
- Machine Mist Collection
Smart Industrial Air Filtration
Industrial air filtration systems play a crucial role in maintaining air quality by capturing dust, welding fumes, wood dust, and airborne particles from food processing facilities. However, traditional filtration systems operate continuously, leading to excessive energy consumption, increased maintenance costs, and limited visibility into system performance.
Hastings’ IVEC Control products address these challenges by optimizing the efficiency of air filtration systems, helping businesses save thousands of dollars annually in energy costs. Manufacturers seek not only to maximize these savings but also to ensure their systems are effectively improving air quality.
The Hastings IVEC team recognized an opportunity to leverage data from their air filtration control products to gain deeper insights into system performance, enhance maintenance services, and provide customers with valuable analytics—particularly tracking energy cost savings compared to conventional filtration systems.
Scaling a Proof of Concept
Initially, Hastings developed an in-house solution that combined hardware gateway functionality with custom software. While this approach demonstrated the potential value of data-driven insights, it fell short in performance and features. Additionally, each installation was manual and time-consuming, highlighting the need for a more scalable and efficient solution.
“We now know what we know and what we don’t know”
Key stakeholder, in an early meeting with Exosite.
Improvements required additional custom development, every update was time-consuming to deploy, and ongoing maintenance pulled resources away from core engineering—making it clear they needed a more scalable, sustainable, off-the-shelf solution.
Strategic Decision
After exploring various solutions, Hastings selected Exosite’s Industrial IoT Platform and ExoSense condition monitoring solution to power their IVEC Command remote monitoring product. Exosite’s ease of use, robust functionality—including real-time and historical data visualization, user permission controls, and hierarchical management—made it the ideal choice.
Exosite collaborated with Hastings through a phased approach:
- Pilot Proof of Concept: Hastings was able to quickly implement a proof of concept to showcase the solution internally, gain stakeholder buy-in, and validate the required functionality.
- Integration & Migration: Exosite supported the seamless migration of existing in-field IoT gateways for their equipment controls to the Exosite IIoT platform, ensuring a smooth transition from the legacy system.
- Scalable Rollout: Hastings developed templates and workflows on the platform to streamline customer onboarding.
- Ongoing Roadmap: Hastings continues to work with Exosite to expand functionality, leveraging their deep expertise in air filtration to enhance customer insights and services.
A key advantage of the system is its adaptability to the varied and custom configurations of industrial air filtration systems. ExoSense’s flexibility allows digital twin assets to be tailored to specific use cases, available edge data, and customer visualization needs. Additionally, Exosite developed an edge configuration tool that enables IoT gateways to manage multiple units within a facility, reducing hardware costs and improving scalability.
“The solution has been so easy to use. There has been really positive feedback from customers. One customer started out saying ‘I don’t want to pay for anything. What can you give me for free’ and by the end of the call, they wanted a quote for 10 year minimum and lifetime.”
Jody M.
Director of Project Management/Controls
Innovation for a Mechanical and Controls Organization
With a feature-rich and scalable solution, Hastings was able to develop its business model around the remote monitoring capabilities of IVEC Command. By partnering with Exosite, they could focus on delivering business value rather than investing time and resources into building and maintaining the underlying technology.
Hastings Organizational Benefits
| Established a revenue-generating subscription model centered on remote monitoring, delivering ongoing value to customers. | |
| Enhanced customer engagement through proactive maintenance insights and guidance to optimization efficiency. | |
| Strengthened technology offerings, maintaining a competitive edge in the industry. | |
| Allowed Hastings’ team to focus on core technology advancements and business growth. | |
| Reduced the time for for team members to onboard new customers and to administrate the solution. |
Benefits for their Customers
| Enabled real-time tracking of energy savings and actionable insights for optimizing system performance, reducing energy consumption, and contributing to sustainability initiatives. | |
| Provided facilities with monitoring, tracking, and reporting tools to ensure a safe work environment through improved air quality management. | |
| Minimized downtime by leveraging predictive maintenance, reducing the risk of equipment failures. |
Hastings IVEC Command
IVEC COMMAND
CLEAN AIR. ONLY SMARTER.
Peak Performance from Peak Intelligence
Manage all aspects of your industrial air filtration systems with the IVEC Command. The IoT (Internet of Things) for your facility plus technology that gives you an advantage. Clean Air. Only Smarter.
Increase productivity and reduce downtime - Maximize the ability of preventive maintenance to thwart potential equipment failures
Troubleshoot - Identify problems quickly and automatically get the information and assistance you need to correct issues in minutes
Generate dynamic reports - Pull reports regarding the overall efficiency of the system. Get overviews of how the system is functioning and analyze energy/cost savings
Receive remote access and alerts - Access/view system metrics and receive warnings about system faults no matter where you are
Lower costs - Boost maintenance efficiency and reduce time needed for support/ diagnostics
Leverage Outside Resources - Outsource maintenance to IVEC or other distributor to lower overhead and free up maintenance staff
About Hastings
Creating a Cleaner Workplace
Hastings Air Energy Control is a manufacturer and full-service provider of process ventilation systems, vehicle exhaust removal systems, air filters and energy saving ventilation controls. They offer a comprehensive range of state-of-the-art industrial ventilation & air filtration energy control systems designed to elevate the air quality in industrial settings.
With a commitment to innovation, efficiency, and sustainability, their solutions are engineered to exceed industry standards, ensuring a healthier and safer environment for your workforce.
Why companies choose Hastings Air Energy Control?
- Compliance Regulations
- Customer Service
- Sustainability
- Technology Experience Center
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