Projects
At Kensan, everything revolves around progress; not just in theory, but especially in practice. Discover how we work together with clients to turn insights, technology, and collaboration into concrete results.
From maintenance challenge to a data-driven factory
What started as a maintenance question evolved into a long-term partnership and the foundation for the Asset Health Monitor. Together with Primus, Kensan developed a data-driven way of working where people, machines, and insight come together.
Primus’ initial question was clear: improve the reliability of their machines and establish a maintenance plan.
However, the analysis revealed critical issues within production.
A simple maintenance adjustment was not enough. Greater insight and automation were needed to achieve truly predictable operations. This led to a collaboration where maintenance, data, and innovation went hand in hand.
Kensan started with Asset Management, establishing a structured maintenance plan and identifying the most critical assets. From there, the focus shifted to automation and data-driven insights to improve maintenance planning and detect failures earlier.
The results and learnings from this trajectory later became a key foundation for the development of the Asset Health Monitor.
Primus now has a single system that provides real-time insight into machine performance. This resulted in 33% higher availability, 21% lower maintenance costs, and 18% improved product quality. The collaboration not only transformed their factory, but also helped shape Kensan’s direction of progress through co-creation.
From data to predictive maintenance
At the Exolum Amsterdam terminal, daily operations focus on the reliable handling of fuels in a complex, safety-critical environment. What started as a focused maintenance question evolved, together with Kensan, into a data-driven pilot exploring how machine learning can use data to better understand failures and prevent downtime.
The vapour recovery unit (VRU) at Exolum in Amsterdam is essential for emission control and operational continuity at the terminal. The installation experienced recurring disruptions in the booster pumps, with causes that were difficult to identify. Exolum wanted to explore whether process and vibration data could help better understand contamination and prevent downtime.
Kensan analysed historical process and vibration data using machine learning to identify patterns preceding performance degradation. The analysis revealed that specific anomalies were linked to early-stage contamination in the filter beds, later confirmed through inspection. Based on these insights, Exolum, Kensan, and Weidmüller are now working together on a real-time Early Warning System using Edge ML.
The pilot provided Exolum with a data-driven understanding of the VRU for the first time: which signals indicate early-stage contamination or blockage, and which conditions increase the risk of disruptions. This created a concrete starting point to plan maintenance more effectively and detect risks earlier. The next step is to expand towards a real-time application, allowing data-driven insights to be structurally integrated into the maintenance process.
From process insight to Vision ML-driven quality control
For Ahold Delhaize Coffee Company, Kensan brought together maintenance, process data, and quality information in one clear system: the Asset Intelligence Platform through the Asset Health Monitor and the Asset Energy Monitor. This gave the team greater control over performance, even with older specialised machines where experience and intuition had traditionally been leading.
Ahold Delhaize Coffee Company operates unique production lines that have been adapted and expanded over the years. The installations are reliable, but require specialised maintenance and deep insight into their behavior. The question to Kensan was how to better manage these machines—without major replacements—and with stronger alignment between maintenance, process, and quality.
Kensan brought together maintenance data, process information, and quality measurements into one central system: the Asset Intelligence Platform. This created a single shared view for operators, technicians, and quality teams. It enabled better understanding of performance and deviations, and allowed knowledge from the shop floor to be structurally connected with data.
The Asset Health Monitor now serves as a shared foundation for maintenance, production, energy use, and quality. Decisions are made based on aligned insights rather than isolated signals or experience alone. This leads to greater predictability in operations, fewer surprises in the process, and a strong foundation for continuous improvement where expertise and data reinforce each other.
Automation for the future of hydrogen
What started as a focused automation request evolved into an innovative project in the hydrogen industry. For Technip Energies, Kensan contributed to a pilot plant for cracking ammonia (NH₃) into hydrogen (H₂), a technology playing a key role in the energy transition. Kensan delivered a control system that combines safety, flexibility, and full digital control.
The ammonia cracker was designed as a pilot installation to validate new process technologies. Technip Energies initially asked Kensan to develop the PLC logic, but it quickly became clear that the system’s complexity required an integrated automation layer to make the entire process manageable.
Kensan designed and built a control system that functions as a full SCADA system. The solution combines control logic, visualisation, and remote operation, with the ability to collect and analyse process data. Through close collaboration, the installation was safely commissioned with full control over the process.
The pilot installation can now be safely and flexibly controlled and monitored. Adjustments to the test setup can be implemented easily without major changes to the control system. This accelerates experimentation, increases insight into the process, and supports Technip Energies in advancing hydrogen technologies.
Smart technology for circular waste streams
What started as a prototype evolved together with Kensan into a professional solution that helps organisations and consumers separate waste more effectively. With a user-friendly scanner, a cloud-based application, and a data-driven dashboard, Wast-e makes circularity tangible and practical.
Wast-e developed a smart waste scanner that determines, based on barcodes and QR codes, which waste stream a package belongs to. The challenge was to evolve this concept into a reliable, scalable solution that provides users with immediate feedback while delivering valuable insights for companies and municipalities aiming to make their waste streams more sustainable.
Kensan developed the prototype into a fully functional scanner with a clear color display for immediate user feedback. On the backend, Kensan built a cloud-based application that processes and manages data from all scanners. This data is presented through a clear dashboard, providing insight into waste streams, usage patterns, and opportunities for improvement.
By combining technology, data, and design, a complete ecosystem was created that makes waste separation understandable and measurable. Organisations gain control over where waste streams originate and how behavior can be influenced. In this way, Wast-e not only enables better separation, but above all better understanding, with Kensan as a partner that translates data into insight and impact.
Reliability in an aging infrastructure
Many wastewater treatment plants in the Netherlands date back to the 1970s and are nearing the end of their lifespan. Waterschap Limburg (WBL) faces the challenge of keeping these installations running reliably and continuously. Kensan supported WBL in gaining better insight into the technical condition of their assets and in setting up a future-proof maintenance organisation.
WBL manages dozens of installations that operate around the clock. Many of these are reaching a stage where maintenance and replacement are becoming increasingly urgent. The question to Kensan was how to structure the maintenance organisation so that aging assets remain reliable, while also working toward a future-proof approach.
Kensan analysed existing studies, maintenance data, and asset information to identify risks, knowledge gaps, and organisational bottlenecks. This included assessing the completeness of the asset base, maintenance processes, and available capacity. Based on these insights, Kensan developed a plan aligned with Asset Management principles, focusing on lifecycle thinking, risk-based prioritisation, and clear roles across strategic, tactical, and operational levels.
The result is a clear and well-founded plan that enables Waterschap Limburg to ensure the continuity of its installations. Not by immediate replacement, but by planning smartly, making risks transparent, and structurally embedding knowledge. The approach brought clarity, control, and direction, and laid a strong foundation for the further professionalisation of Asset Management within the organisation.
Smarter maintenance in a complex process environment
Shell continuously works to improve reliability and safety within its installations. Kensan provided expertise and support to optimise maintenance processes and reduce risks.
Within Shell’s industrial installations, the bar is set high: maximum availability and minimal risk. The request to Kensan was to support the improvement of maintenance processes and strengthen the alignment between engineering, data, and execution. The focus was not on new systems, but on creating better insight, structure, and coordination within an existing, complex environment.
Kensan mapped the existing maintenance processes and analysed where improvements could be made in planning, execution, and evaluation. By applying systems engineering principles, technical data, procedures, and maintenance tasks were better aligned.
In addition, focus was placed on knowledge transfer and clear role allocation between departments, strengthening the organisation in a sustainable way.
The collaboration resulted in greater predictability of maintenance activities and more efficient use of resources and capacity. Failures were resolved more quickly, and collaboration between teams improved significantly. Shell now has a maintenance structure that meets the highest safety standards while enabling continuous improvement.
Reliable drinking water, even at sea
Hatenboer Water develops installations that treat seawater into drinking water for ships and offshore locations. Kensan was asked to contribute to improving maintenance, quality, and reliability of these systems.
Hatenboer Water delivers water treatment installations worldwide for both civil and maritime clients. The systems are becoming increasingly complex, while often operating under demanding conditions. The question to Kensan: how do we ensure these installations remain reliable over the long term, and how do we translate that into a maintenance strategy that fits our customers?
Kensan conducted an analysis of existing reliability studies and the expected lifespan of critical components. Based on Asset Management principles, recommendations were made on maintenance intervals, risks, and spare parts. The focus was on quality and depth of the process, providing better insight into what is needed to keep installations reliable, without adding unnecessary complexity.
The advice provided Hatenboer Water with a better balance between performance, cost, and risk. This resulted in a clear maintenance plan applicable across different customer types, including the most critical environments. A collaboration in which Kensan’s Asset Management expertise supported the development of a well-founded lifecycle strategy for the entire lifespan of the installation.
Data Value Drechtsteden
At the Duurzaamheidsfabriek, Kensan collaborates with education and industry on the Data Value Drechtsteden program, a project where data, technology, and people come together to shape the industry of tomorrow.
The Drechtsteden region aims to demonstrate what data analytics and smart maintenance mean in practice. Education, industry, and government joined forces to share knowledge and accelerate innovation. Kensan was asked to contribute to the program and develop real-world projects that bring students and companies closer together.
Together with partners at the Duurzaamheidsfabriek, Kensan developed several demonstration setups focused on sensors, predictive maintenance, and energy consumption. These projects show how machine data can be translated into insights for maintenance, efficiency, and sustainability. By connecting theory and practice, students and companies learn how data truly adds value in an operational environment.
Dozens of students and professionals participated in projects within Data Value Drechtsteden. For Kensan, this project is an opportunity to share knowledge, stimulate innovation, and inspire the next generation of engineers to make a difference with data.
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