Overview

A major mining operation was experiencing inconsistent throughput visibility across several critical ore conveyors feeding downstream crushing and processing operations.

The facility had traditionally relied on mechanical belt scales to estimate material flow rates and production throughput. However, harsh operating conditions throughout the mine created ongoing reliability and maintenance challenges.

Overview

Artificial Intelligence is transforming the way data centers operate, but it is also dramatically increasing the demand for power, cooling, and environmental monitoring. As AI workloads continue to expand, data center operators are facing new challenges around energy consumption, uptime protection, thermal management, and refrigerant leak prevention.

At TechStar, we work with facilities across critical infrastructure industries to help solve these operational challenges with reliable monitoring, detection, and automation solutions from MSA Safety / Bacharach.

AtTechStar, we believe great measurement starts with the right technology and ends with solutions that are reliable, scalable, and supported long after startup. That’s why we’re excited to expand our analytical portfolio through our representation of Process Insights, bringing together a broad range of proven analytical technologies. 

As the year-end holiday season approaches, industrial facilities face unique safety challenges, and strong fire and gas detection systems are critical to maintaining a safe, compliant workplace. A proactive, multi-layered detection strategy not only supports safety during colder temperatures and reduced staffing, it also helps ensure reliable hazard monitoring throughout year-end operations and into the New Year.

In water and wastewater operations, knowing exactly what’s happening inside your tanks, wells, and channels is critical. Level measurement ensures pumps run efficiently, tanks don’t overflow, and solids are processed safely, all while helping you meet strict environmental regulations.

At TechStar, we work alongside operators and engineers to design level measurement systems that deliver dependable performance in the toughest conditions. From clean water tanks to sludge thickeners, we provide solutions built for accuracy, integration, and long-term reliability.

Accurate flow measurement is foundational to operational excellence, especially in separator systems. Whether you’re dealing with gas, water, or multi-phase streams, reliable data drives production performance, environmental compliance, and cost control. That’s why we’re excited to showcase the latest insights from Fox Thermal in the newly released “Separator Application Optimizer.”

In the evolving landscape of water treatment, operational efficiency and reliability are paramount. The Onondaga County Water Authority (OCWA) in New York serves as a prime example of how modernizing control systems can lead to significant improvements.

We’re excited to announce the release of the new Application Optimizer for Clinker Coolers, a document designed to help cement manufacturers optimize their clinker cooler operations through precise airflow measurement. This Application Optimizer maps out key airflow measurement points across the clinker cooler system, offering actionable insights to improve cooling efficiency, reduce energy consumption, and enhance clinker quality.

With MSA’s TruCal® technology, available on XCell® hydrogen sulfide (H₂S) and carbon monoxide (CO) gas sensors, you get a smarter, more proactive approach to gas detection. TruCal helps monitor sensor health automatically, so you don’t have to wait until the next scheduled calibration to find out something’s wrong. Whether you’re running critical infrastructure or a high-demand industrial facility, TruCal helps give you added peace of mind, right where it counts: between calibrations.

At TechStar, solving process challenges goes beyond instrumentation, it means delivering complete, integrated automation solutions. With years of experience designing and implementing custom systems, our team brings advanced automation to every corner of industry, helping you operate smarter, safer, and more efficiently.

Here’s how different industries are optimizing their operations through custom automation: