Digital technologies are rapidly evolving and reshaping nearly every area of modern operations. As organizations rely on advanced tools, a reliable network becomes essential before deploying AI, machine learning, or digital twins. Even the most advanced analytics can’t deliver meaningful insights without a dependable connection. Ensuring enough ports are in the right places keeps devices connected while minimizing potential points of failure. This is a detail that often gets overlooked in the race toward digital transformation.
In modern warehouses, automated conveyor systems rely on a growing number of sensors to keep production running smoothly. These sensors communicate between conveyor control units, scanners, and a central monitoring system. One distribution centre successfully deployed reliable Brainboxes network switches to connect its systems. Initially, new devices were easily added by daisy-chaining 4-8 port switches. While effective at first, the team found that this approach wasn’t as scalable as other options. Over time, it created a fragmented and increasingly fragile network. Managing connectivity became a constant challenge, and troubleshooting network issues consumed far more time than anticipated.
The team aimed to gain predictive insights into conveyor health, equipment performance, and product flow. However, the physical network became a limiting factor. Switches were scattered along the conveyors, “dead spots” appeared where ports were maxed out, and there was no room for adding additional sensors. Any single switch failure could take multiple devices offline, making reliable predictive maintenance nearly impossible.
The distribution centre addressed the problem by replacing the small switches with a single Brainboxes Hero Ethernet 16 Port switch on each conveyor line. This created an organized, robust, and scalable network. The higher port count eliminated the daisy-chain complexity while providing room for future sensors or upgrades without a network redesign. The rugged, industrial design of Brainboxes’ Hero Ethernet switches allows them to operate reliably in harsh conditions, whilst the integrated mounting options reduce cable clutter and potential points of failure.
With the physical network configured, and less time spent on fixing network issues, the team can now focus on collecting accurate data and turning it into actionable, predictive insights; streamlining conveyor operations to improve sorting, routing, product tracking, and enhancing productivity.
Modern maintenance relies on data from every part of a facility, but collecting quality data starts with a strong physical network. Brainboxes industrial 16-port Hero Ethernet switches provide the connectivity and resilience necessary before AI or machine learning ever come into play.
Predictive maintenance begins not just with software, but with the dependable connectivity of Brainboxes Hero Ethernet switches, designed to deliver data exactly where it’s needed.
