Three lessons from rolling out predictive maintenance across 40 sites
Two years, 40 plants, 11 countries. What worked, what did not, and what we would do differently.
Nov 4, 2026 - Halden Systems Newsroom
Industrial automation and energy
Systems for the plants that keep the world running
Since 1986 Halden has designed, built and maintained the control and energy systems behind factories, utilities and process plants. 12,400 people, 38 countries, 1,900 plants under service.
- People worldwide
- 12,400
- Countries with a Halden presence
- 38
- Plants under lifecycle service
- 1,900+
- Founded in Zurich
- 1986
What we build
Five practice areas, delivered by regional teams who stay with the plant for its working life.
Plant automation
Control systems, safety instrumented systems and plant-wide integration for new builds and brownfield upgrades.
Energy management
Monitoring, load management and on-site generation that cut energy cost and reported emissions.
Predictive maintenance
Sensor data and models that flag failing equipment weeks before it stops the line.
Lifecycle services
Spares, upgrades, training and 24 hour support contracts with response times in writing.
OT cyber security
Segmentation, monitoring and incident response built for operational technology, not borrowed from IT.
Global delivery
Engineering centres in Zurich, Pune, Monterrey and Singapore and service teams in every region we sell to.
How an engagement runs
- 1
Site assessment
A solutions engineer walks the plant with your team and writes up constraints, risks and options.
- 2
Design and build
Fixed scope, named engineers, factory acceptance testing before anything ships to site.
- 3
Commission and support
Commissioning with your operators, then a service contract with response times in writing.
From our customers
"The predictive maintenance rollout across our 14 sites paid for itself in the first unplanned stop it prevented."
"Halden's team has been on our plant floor for eleven years. They know it better than some of our own people."
"The energy management system cut our reported scope 2 emissions by 18 percent in a year, with no change to output."
From the blog
Customer story: how Nordfjord Paper cut unplanned stops in half
Fourteen mills, three countries, 900 monitored assets. Ingrid Solberg on what changed and what she would tell another operations lead.
Oct 30, 2026 - Halden Systems Newsroom
Halden expands its Pune engineering centre
A second building and 600 additional engineering roles over three years, focused on software and data for plant systems.
Oct 23, 2026 - Halden Systems Newsroom
Common questions
Do you work with equipment from other vendors?
Yes. Most of the plants we serve run a mix of vendors. Our systems integrate with the major control and drive platforms and we maintain them alongside our own.
What does a service contract include?
Named engineers, response times in writing, spares holding, scheduled upgrades and 24 hour support. Contracts are shaped to the plant; see Lifecycle services or talk to your regional team.
How do you handle safety-critical systems?
Safety instrumented systems are designed and verified to IEC 61511 by certified engineers, with independent review before commissioning. See Quality and safety.
Where are you based?
Headquarters in Zurich, engineering centres in Zurich, Pune, Monterrey and Singapore, and service teams in all 38 countries where we operate.
Talk to a solutions engineer in your region
Tell us about your plant and we will come back with options, not a sales deck.
Contact sales