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Manufacturing and Heavy Industry operations around the world rely on their machinery to get the job done, efficiently and effectively. The cost of equipment failure and the resulting unplanned downtime has serious consequences for the bottom line, with medium unplanned downtime costs approximately $125,000 per hour. When inflationary pressures, supply chain demands and raw material costs are factored in, unplanned downtime costs for Heavy Industry were calculated as $59 million per year in 2023.

Faced with the need to minimize the business impact of unplanned downtime for critical equipment, industries with heavy assets and significant downtime costs, such as oil & gas and mining, are leading the way in adopting Predictive Maintenance solutions.

By incorporating satellite connected IoT sensors, Heavy Industries operating in remote locations can reliably monitor machinery in real time and react quickly to avoid equipment failures and keep assets operational. The data from satellite-connected sensors on equipment forms a vital component of deploying Predictive Maintenance programs in industries with high asset costs.

What is Predictive Maintenance?

Predictive Maintenance (PdM) is a proactive, data-driven approach that uses advanced technologies – such as condition monitoring, machine learning (ML) and IoT devices – to anticipate equipment failures and schedule maintenance before disruptions occur. By analyzing real-time data from sensors installed on machinery, PdM identifies early signs of wear, faults, or deterioration, enabling timely intervention to prevent costly downtime.

Unlike time-based or reactive maintenance, PdM optimizes equipment performance by triggering maintenance tasks only when specific conditions indicate a need. This approach improves equipment reliability, reduces maintenance expenses, and extends the lifespan of assets. AI-powered analytics and IoT-enabled sensors track key metrics like temperature, pressure or vibration, providing continuous insights into machine performance. When thresholds are exceeded, PdM systems issue alerts or initiate maintenance work orders.

The goal of PdM is to enhance operational efficiency by minimizing unplanned downtime, lowering maintenance costs, and ensuring asset reliability. Industries such as manufacturing, energy, and transportation rely on PdM to align maintenance activities with actual equipment conditions, maximizing productivity and supporting cost-effective, sustainable operations.

What is the Difference between Predictive and Preventive Maintenance?

Although often used interchangeably, Predictive Maintenance (PdM) and Preventive Maintenance (PM) are distinct approaches to equipment upkeep, each suited to different operational needs.

Preventive Maintenance follows a scheduled approach, performing maintenance at regular intervals based on time or measurable usage units, such as engine hours or production cycles. This method ensures equipment is inspected and maintained before issues arise, but it does not consider the actual condition of the asset.

For instance, a Mining operation may replace drill components every six months, regardless of whether those components show signs of wear. While this minimizes the chance of failure, it may result in premature replacements or unnecessary downtime.

Predictive Maintenance leverages real-time data from IoT sensors and advanced analytics to monitor the actual condition of assets. Maintenance is performed only when necessary, based on insights into potential failures or performance degradation.

For example, IoT sensors on a Combine Harvester may detect rising temperatures or irregular vibrations, indicating wear and tear. Predictive maintenance enables technicians to address the issue before a failure occurs, minimizing downtime and repair costs.

Comparing the Two Approaches

Aspect

Preventative Maintenance

Predictive Maintenance

Basis for Maintenance

Time or Usage Intervals

Real-Time Condition Monitoring and Analysis

Frequency

Regular, Fixed Schedule

As Needed, Based on Data Insights

Costs

Lower Initial Costs, Higher Cumulative Costs

Higher Initial Investment, Lower Long-Term Costs

Downtime

May Require Equipment Stoppage

Often Avoids Downtime by Scheduling During Low-Impact Periods

Efficiency

May Result in Unnecessary Maintenance

Targets Specific Issues, Optimizing Resources

Types of Predictive Maintenance

There are three distinct types of Predictive Maintenance: Indirect Failure Prediction, Anomaly Detection, and Remaining Useful Life (RUL). Each approach differs in its desired objectives, the analytical methods used, and the type of information output provided.

Image adapted from the IoT Analytics Asset Performance & Predictive Maintenance Market Report 2023–2028

Indirect Failure Prediction
Estimates equipment health by calculating a ‘health score’ based on known maintenance requirements, operating conditions and historical performance data. When sufficient data is available, supervised machine learning can be applied to refine the predictions. This approach is scalable since it relies on manufacturer specifications, and it is cost-effective because it uses existing sensors.

Its dependence on large volumes of historical data may render it unsuitable for industries like heavy machinery, where high downtime costs necessitate more immediate and accurate insights.

Anomaly Detection
Identifies potential failures by detecting deviations from normal operating conditions in real time. Unlike methods that require historical data, it relies on current sensor data, making it particularly suited to organizations without extensive machinery usage records. This approach improves predictive accuracy by considering real-time environmental and operational factors rather than predefined maintenance parameters set by the manufacturers.
The risk of false positives can pose challenges, as unnecessary alerts may disrupt operations and complicate machine learning algorithm performance.

Remaining Useful Life (RUL)
Focuses on predicting the time left before equipment failure based on specific machine metrics such as operational hours, distance traveled, or activity cycles. By analyzing sensor data, this method identifies condition indicators that highlight whether the equipment is performing as expected or if faults have accelerated its degradation. RUL models are trained using system data collected under known conditions and applied to predict outcomes under new or variable circumstances.

While this method is highly robust and reliable, it requires detailed, high-quality data for accurate predictions, making it particularly effective for critical equipment in complex environments.

The Benefits of Predictive Maintenance

Predictive Maintenance brings many benefits to organizations through its advanced approach to equipment upkeep, using technology and data analysis to improve asset reliability and efficiency. By identifying potential issues before they lead to failures, PdM helps organizations reduce downtime, optimize resources, and maintain safer working environments.

Research, including findings from the US Department of Energy, highlights the tangible impact of Predictive Maintenance. Compared to preventive maintenance programs, it offers cost savings of 8% to 12%, and when compared to reactive maintenance, cost savings increase to 30% to 40%. These programs also enable a reduction in maintenance costs by 25% to 30% and minimize equipment breakdowns by 70% to 75%.

In addition to cost savings, PdM improves operational efficiency by reducing downtime by 35% to 45% and increasing production capacity by 20% to 25%.

40%

Cost Savings

30-45%

Downtime Reduction

75%

Fewer Equipment Breakdowns

How to Implement Predictive Maintenance

1. Establish Baselines and Data Collection

Baseline performance metrics are identified for the assets by monitoring its condition to set the normal performance benchmarks. Once the baseline is established, sensors are installed to capture real-time data, enabling continuous performance monitoring.

2. Install IoT Sensors on Equipment

IoT sensors are installed on critical equipment to monitor various parameters such as vibration, temperature, pressure, and noise. These sensors continuously collect data on the equipment’s condition and the data gathered is then transmitted to a centralized system for analysis.

3. Data Integration and System Setup

The data collected from the IoT sensors needs to be integrated with the PdM system. This involves connecting the sensors to a computerized maintenance management system (CMMS) or a remote dashboard which allows for real-time monitoring and data analysis.

4. Set Maintenance Thresholds and Automate Alerts

Organizations need to define thresholds for acceptable performance levels. When these thresholds are exceeded, the system automatically triggers maintenance alerts, enabling timely interventions before equipment failure occurs.

5. Select and Implement the Right Analytics Tools

An analytics platform is required to handle the large volumes of data, apply predictive models, and generate actionable insights. Machine learning and AI algorithms are crucial for analyzing sensor data and predicting future equipment failures based on historical data.

6. Develop Predictive Models and Train the System

Predictive models are developed using historical data, maintenance logs and sensor data to forecast future equipment behavior. These models are trained to identify patterns in the data that may signal the onset of failure.

7. Integration with Existing Maintenance Systems

The PdM system is integrated with existing workflows, maintenance management systems, and enterprise resource planning (ERP) systems. This enables seamless communication across platforms and allows for data-driven decision-making.

8. Monitor and Optimize the Program

After implementation, the PdM program should be monitored to evaluate its effectiveness. Continuous data collection and model refinement will help improve prediction accuracy over time.

Industrial Applications of Predictive Maintenance

Predictive Maintenance is becoming increasingly common practice in asset-intensive industries that depend on their large, complex machinery. For industries with assets in remote locations or critical communication requirements, satellite connected IoT devices can transmit real-time sensor data for PdM programs.

Energy and Utilities

The risk of equipment failure in energy production and utilities management can lead to significant financial losses and customer dissatisfaction. Power plants, wind farms, and utility grids employ PdM programs to ensure the continuous operation of critical assets like turbines, generators, and transformers. IoT sensors monitoring parameters such as vibration, temperature, and pressure are used to detect early signs of failure.

By analyzing these data points in real time with advanced predictive models, utility providers can prevent catastrophic failures, optimize energy production, and ensure compliance with regulatory standards. This is particularly important in industries where unexpected downtime can have widespread consequences on both financial performance and customer trust.

Railways and Transportation

PdM is crucial in the transportation industry for ensuring the safety and reliability of infrastructure such as railway tracks, trains, and airport ground equipment. IoT sensors on trains and other critical assets monitor parameters like pressure, temperature, and vibration to detect early signs of wear or failure.

For example, PdM can be used to monitor brake systems or detect track deformations, preventing accidents and service interruptions. By integrating sensors with automated maintenance management systems (CMMS), transportation companies can schedule repairs before a component fails, enhancing passenger safety and reducing operational disruptions.

Oil and Gas

In remote locations such as offshore platforms or desert pipelines, Oil and gas operations face unique challenges in maintaining equipment. PdM is highly beneficial in these situations, as it helps companies remotely monitor the condition of critical machinery like pumps, compressors, and valves.

Satellite-connected IoT sensors track parameters such as pressure, temperature, and vibration to detect signs of imminent failure. Real-time data is sent to cloud-based platforms for analysis, and predictive algorithms generate alerts to maintenance teams, allowing them to address issues before they result in costly downtime or safety hazards.

Mining

With Mining machinery operating in harsh conditions, the risk of unexpected breakdowns can lead to costly delays and safety hazards. Predictive maintenance helps to monitor heavy equipment such as crushers, drills, and loaders, which are critical to mining operations.

Satellite-enabled IoT sensors measure variables like temperature, pressure, and vibration, providing continuous health checks of the machinery. Predictive models analyze these data streams to identify wear patterns and predict when maintenance is required.

Sensor Technologies in Predictive Maintenance

Predictive Maintenance utilizes a range of sensor technologies to monitor the condition of equipment and to detect and address potential failures before they lead to unplanned downtime.

Infrared Thermography

Also known as thermal imaging, infrared cameras identify heat spots which can indicate issues such as friction, electrical resistance, or misalignment in mechanical systems. It is particularly valuable in identifying worn-out components or malfunctioning circuits that tend to overheat.

Infrared thermography allows for real-time monitoring without disrupting machine operation and is frequently used in industries like power generation to track turbine blade conditions and ensure equipment runs efficiently.

Acoustic Monitoring

Using specialized equipment, maintenance personnel can detect ultrasonic or sonic emissions from machinery, which may indicate leaks, electrical discharges, or mechanical wear. Sonic monitoring is typically applied to lower-speed equipment, while ultrasonic analysis is more accurate and applicable to both low- and high-speed machinery.

Ultrasonic analysis is widely used in industries like construction and heavy equipment operations, where hydraulic systems and machinery require constant monitoring to ensure seamless operation and prevent project delays.

Vibration Analysis

Sensors track vibration patterns that help technicians identify potential issues like misalignment, unbalanced components or bearing failures in high-speed rotating equipment, such as motors, drills and fans.

Each machine has a unique vibration signature, and deviations from this pattern can be a strong indicator of mechanical problems. The ability to monitor vibration in real-time allows for early intervention, preventing costly repairs and downtime.

Oil Analysis

By analyzing oil for contaminants, viscosity changes, and particle counts, technicians can pinpoint wear and tear in machine components. Chemical analysis of oil can also reveal overheating or chemical degradation, providing early warnings of issues that could lead to failure.

This technology is often used in heavy industries, such as energy production or oil drilling, where machinery components are subject to extreme operating conditions.

Current and Voltage Sensors

These sensors track electrical characteristics like overloads, short circuits, and failing components. In industries such as mining or energy, where electrical systems are critical, monitoring these parameters ensures safety and minimizes downtime caused by electrical failures.

For example, real-time analysis of electrical data in mining operations can help identify potential issues in equipment like excavators or conveyors, allowing operators to address problems before they cause equipment failure and disrupt production.

Predictive Maintenance and Satellite IoT

For remote operations, such as those found in mining or offshore environments, Satellite IoT becomes a crucial part of the Predictive Maintenance Program. When assets are located in areas with unreliable or no cellular connectivity, traditional IoT solutions relying on cellular networks may fail to transmit vital data. Satellite IoT solutions overcome this challenge by enabling real-time data transmission via satellite, ensuring that assets can be monitored regardless of their location or environment.

Beyond just sensor data collection, Satellite IoT can enable remote control of assets. If an asset is detected to be operating in an unsafe condition, it can be remotely shut down to prevent catastrophic damage or safety incidents. This combination of real-time monitoring and remote intervention significantly enhances worker safety and helps avert equipment breakdowns before they escalate into more serious issues.

Get in Touch

At Ground Control, we design and build Satellite IoT devices leveraging the Iridium global network, providing reliable real-time data transfer from anywhere on Earth. Our feature-rich IoT platform, Cloudloop, can monitor and analyse sensor data and offers a simplified and well-documented API to connect to your existing Predictive Maintenance and Asset Performance Management (APM) toolkits.

With over 20 years of experience, we can help you make the best choices based on your requirements.

As the world of satellite IoT connectivity rapidly evolves, selecting the right network for your remote application has never been more important — or more complex. Whether you’re deploying environmental monitoring devices, controlling unmanned systems, or tracking remote assets, understanding your options can save you significant time, money, and operational effort.

That’s why we created a comprehensive guide to help you navigate this dynamic landscape and make informed choices. The highlights are in this blog post; read the eBook to digest the in-depth version.

Read Free eBook

The Expanding Satellite IoT Landscape

In recent years, satellite networks have undergone a transformation. Established players have diversified their services, offering greater flexibility and more competitive pricing. At the same time, new satellite constellations are launching at a faster rate than ever, introducing innovative services and standards that promise even more possibilities for IoT applications.

This abundance of options is great news, but it also presents a challenge: with so many variables at play, how do you select the best network for your specific needs? That’s where our expertise comes in. Ground Control has spent over 20 years testing and integrating satellite networks to ensure optimal connectivity for our customers. We’ve distilled our knowledge into an easy-to-follow eBook that covers everything you need to consider.

Key Considerations for Choosing a Satellite Network

When evaluating satellite IoT networks, there are several critical questions to ask:

How data-intensive is your application? Understanding your data volume needs is crucial. For instance, message-based services like Iridium Messaging Transport (IMT) are ideal for low-volume, energy-efficient data transmission. On the other hand, IP-based services such as Iridium Certus 100 are better suited for high-data applications like real-time control or video streaming.
Where are your sensors located? Coverage matters. While some networks like Iridium offer truly global coverage, others may not reach polar regions or other remote areas. Additionally, factors like terrain and obstructions can affect the choice between Low Earth Orbit (LEO) and Geostationary (GEO) satellites.
Is your application stationary or mobile? Mobile applications often require LEO networks, as they don’t rely on precise antenna alignment. Conversely, stationary deployments with a clear line of sight to a GEO satellite may benefit from the stability and cost-effectiveness of GEO-based solutions.
How time-critical is your data? Applications requiring real-time data transmission will need well-established LEO networks with IP-based connections. For less time-sensitive use cases, store-and-forward technologies used by some newer LEO networks might be a cost-effective alternative.

Standards-Based vs. Proprietary Networks

One of the most exciting developments in satellite IoT is the emergence of standards-based technologies like LTE Cat 1 and NB-IoT over satellite. These allow a single modem to connect to both cellular and satellite networks, promising cost savings and supplier flexibility. However, these technologies are still in their infancy and come with trade-offs, such as higher power consumption or limited data volumes.

Where you have a combination of relatively high data volumes plus no mains power, proprietary networks offer optimized performance tailored to their specific satellite systems. For instance, message-based protocols like Iridium’s Short Burst Data (SBD) deliver efficient, low-power communication for small data packets, making them ideal for battery-powered IoT devices.

What You’ll Learn in the eBook

Our eBook, How to Choose the Right Satellite IoT Network, dives deeper into these topics and provides actionable insights, including:

A detailed comparison of leading satellite networks like Iridium, Viasat, Starlink, and Globalstar.
Real-world examples of how different networks excel in specific use cases.
A practical framework for evaluating networks based on coverage, latency, power efficiency, and mobility.
Insights into emerging technologies and how they may impact your future connectivity strategy.

By the end of this guide, you’ll have the tools you need to select a satellite IoT network that aligns with your technical and operational requirements.

Read Free eBook

Can we help with your remote IoT application?

We have decades of experience designing and building satellite IoT connectivity solutions, and work with multiple satellite networks to ensure our customers get the right service for their needs.

If you would like expert, impartial advice on your remote IoT application, please get in touch! Complete the form or email hello@groundcontrol.com. We will reply within one working day.

Iridium have just launched their latest satellite transceiver, the Iridium Certus 9704. In this post we’re going to explore how this module compares with other satellite IoT modems, the Iridium 9603 and Certus 9770. We’ll look at ideal use cases for the new transceiver, how to get the best out of the device, and how to get started.

What is the Iridium Certus 9704?

The 9704 is a small, lightweight and low power satellite IoT transceiver that connects to the globally available Iridium satellite constellation.

It leverages Iridium Messaging Transport (IMT), a message-based service which allows users to transmit data packets of up to 100 kB. What is IMT?

What Applications are Suited to the 9704?

The 9704 has been designed to consume very little power, so it’s ideal for remote, battery-powered applications. For example, telemetry from heavy machinery; SCADA readings from unmanned substations or infrastructure; aggregated gateway / hub data; data logger transmissions.

It can also be used for simple UxV commands; stop, start, return etc.

How Does the 9704 Differ from the 9603 Transceiver?

The 9704 module is 34% smaller than the 9603N modem: 31.5 x 42 x 3.8 mm vs. 31.5 x 29.6 x 8.1 mm, and 12 g vs. 11.4 g respectively*.

The 9704 also boasts an 83% reduction in idle power consumption compared to the 9603. The message size for the 9603 is considerably smaller compared to the 9704; 340 / 270 bytes (Short Burst Data) vs. 100 kB (Iridium Messaging Transport). The link speed is also doubled with the 9704; from 2.4 Kbps to 4.8 Kbps.

Applications best suited to the 9603 include asset tracking, environmental monitoring and fleet management; it remains the most cost-effective way to move very small volumes of data using the Iridium satellite constellation. But for many applications, IMT will be a more cost-effective means of transmitting IoT data.

View 9603-Based Products

How Does the 9704 Differ From the 9770 Transceiver?

The Iridium Certus 9770 modem is a more powerful device. It can send data over IMT, but also over IP, creating greater flexibility and making it more suitable for applications where real-time command and control is required – for example, piloting a drone BVLOS.

The 9770 sends data far more quickly; 22 / 88 Kbps vs the 9704’s 4.8 Kbps (Tx/Rx). But this comes with a greater power draw; the 9770 requires 3.5 W to transmit/receive, whereas the 9704 requires just 400 mW*.

The 9770 is also larger and heavier than the 9704; 140 x 60 x 16 mm and 185 g vs. 31.5 x 42 x 3.8 mm and 12 g respectively*.

The Certus 9770 can be used for voice communication, and the 9704 is data only.

Devices utilizing the 9770 transceiver are ideal for remote control of assets such as UAVs and USVs; or when it’s important that data is moved quickly, so any form of alerting mechanism such as remote security or systems failure alarms. They will also be the preferred choice of systems integrators who want the flexibility to switch between IP and message-based transmissions depending on the type of data being moved.

View 9770-Based Products

Which Devices Utilize the 9704 Transceiver?

At the time of writing, you can purchase a 9704 developer kit and build the 9704 transceiver into your enclosure. We are IMT and Iridium experts, having worked with the Iridium development team for decades, and we are here to help you get the best out of Iridium Messaging Transport.

We are prototyping two new devices to leverage the new technology; the RockBLOCK Pro, for IoT applications, and the as-yet-unchristened successor to the RockFLEET, which is our multi-purpose, all-weather tracking and IoT device.

What is Iridium Messaging Transport (IMT)?

Launched in late 2022, IMT is Iridium’s most recent satellite IoT service. It is message-based, which is the most cost-effective and power-economical way to communicate with satellite networks (vs. an IP connection which has a substantial overhead).

With a message-based service, you pay only for the data you choose to transmit, and only when it’s successfully transmitted. However, a drawback of message-based services is that the data has to be reformatted before it reaches your preferred destination; unlike IP-based communication, it isn’t a commonly utilized format.

We built Cloudloop Data to address this challenge. This delivers simplified store and forward IoT messaging between your devices and cloud-based services. Messages can be fanned to multiple endpoints, from cloud providers like Azure and AWS, to IoT dashboards including ThingsBoard and ThingSpeak. You also have the option to consume the decoded data in your own system, through delivery methods including email, MQTT and HTTP webhook.

How to Get Started With the Iridium Certus 9704

We encourage you to contact us to discuss your application; we are Iridium experts, and will provide you with impartial advice on the best airtime, service and hardware to best meet your needs.

We’re responsive, friendly and helpful, and we genuinely love helping people solve their remote connectivity problems, so please get in touch!

*Information on the 9704 is subject to change.

Get in Touch

To get in touch with our team of Iridium experts, please complete the form, email hello@groundcontrol.com, or call us on one of the below numbers.

We will respond to your message within one working day.

UK: +44 (0) 1452 751940

USA: +1.805.783.4600

Heavy industrial sectors have continued to push the boundaries of what is possible in some of the most remote and challenging locations on the planet. Industry 4.0 has been a transformative technological leap for the traditional industries of mining, agriculture, forestry and construction, bringing new monitoring and automation capabilities to the heavy equipment that these sectors rely on.

In remote mining, farming, forestry or construction sites, an equipment breakdown can cost thousands in downtime. For industries operating far from cellular coverage, ensuring machinery stays operational is a challenge that Satellite IoT is solving with real-time data and monitoring. In this blog, we’ll explore how IoT can enable the transformation of heavy machinery operations, tackling issues like maximizing cost of ownership, preventing downtime, and safety and environmental compliance.

Heavy Equipment Total Cost of Ownership (TCO)

Purchasing specialized heavy equipment is a significant investment, and in recent years those costs have been steadily climbing as manufacturers pass on their increased raw material and labor costs. The Capital Expenditure (CapEx) involved means that each machine must be operated effectively, efficiently and within agreed tolerance limits to reduce maintenance costs and prevent costly downtime.

The theft of heavy equipment is also commonplace, with over 11,000 incidents of construction theft reported annually in the US and an average average loss of $35,000 to $45,000 per machine. Theft also has a considerable impact on operational timescales, as well as increased costs to replace or lease equipment.

Worker Safety cost

Hazardous Work Environments

With heavy industry recognised as one of the most hazardous places to work (accounting for 63 per cent of all fatal occupational injuries) worksite safety requirements have, quite rightly, been improving on a global scale as Governments enforce a duty of care on industry operators.

However, it remains that despite these improvements, a diminishing workforce is entering these physically challenging industries based in remote locations. This has led to increased Operational Expenditure (OpEx) to attract high quality skilled candidates.

Environmental and Sustainability Targets

Heavy industry accounts for around a third of global energy consumption and emits a quarter of global Greenhouse Gas emissions. Pressures from Governments to hold businesses to account for their carbon emissions and environmental impacts particularly affect these industries.

To meet agreed environmental commitments, operations may need to invest in technology to analyse the worksite’s impact on the surrounding area and consider upgrading heavy machinery to meet emissions targets.

Operational Complexity

Keeping to contractual timescales on any large project involving heavy machinery is ultimately reliant on the equipment being reliable. Delays in specialist heavy equipment arriving on-site and unexpected breakdowns can lead to extensive project delays and wasted resources, all of which lead to an increased OpEx.

Without clearly-defined logistical operation data to coordinate fuel deliveries and material transport, an entire site could come to a standstill.

Connectivity Limitations

Mining, forestry, farming and construction operations often take place in remote locations with limited or no mobile or cable internet coverage. The cost of connecting fixed or cellular telco equipment or laying cables for site connectivity is often very expensive, especially when real-time communication is required for equipment operations or emergency protocols.

The return on investment for installing a dedicated network on a site which may only be operational for 10-15 years is often poor and can become a negative cost.

Six Innovations in Heavy Machinery Operations

Many of the issues facing industries using heavy machinery can be mitigated against by using technology, data and connectivity.

With satellite connectivity more reliable than cellular in remote locations and increasingly more competitively priced, the cost-effectiveness and profitability of mining, forestry, construction and agriculture operations can be significantly improved and many of the key issues facing the industry can be resolved.

1. Predictive Maintenance

Predictive maintenance is a data-driven approach to keeping heavy machinery operating at peak performance and efficiency. By continuously monitoring on-board sensors for feedback on tire wear, oil and fuel consumption, engine temperatures, hydraulic pressures, vibrations, stability and acceleration, machinery can be proactively inspected and maintained according to usage, rather than reactively when a breakdown occurs.

Satellite IoT devices can transmit real time data on machine usage and even enable a shutdown of equipment if thresholds are exceeded. By planning machine maintenance downtime, preventing failures that could lead to accidents, and monitoring machinery operatives driving behaviour, the operation expenditure of the site can be effectively managed and optimized.

The 2021 McKinsey & Company ‘The Internet of Things’ Report highlighted that in the construction sector, employing IoT applications can improve uptime by 30 to 50 percent and increase throughput by 1 to 5 percent.

An additional benefit of monitoring machinery usage is to provide a better return on the CapEx of the machinery when the equipment is sold at the end of the project.

2. Remote Monitoring

Remote monitoring of site personnel and equipment can enable the operational efficiency of worksites, as well as ensure the safety of all workers on-site. With satellite-connected asset trackers on equipment and team members, remote operations centres can use geo-fencing capabilities to keep personnel and heavy machinery apart using safety zone alerts. Should a team member stray into the path of an oncoming vehicle, both the individual and the driver can be alerted to the potential risk.

Satellite IoT enabled sensors can detect worksite ambient conditions to ensure staff and machinery are not exposed to extreme working temperatures, strong winds, excessive rainfall or poor air quality. By encouraging and demonstrating a commitment to site safety, labor recruitment can be improved.

Site operations can be further optimized through monitoring of raw material tanks and silos (e.g. concrete and chemical reagents), machinery fuel consumption, generator fuel levels and final product storage and collection (e.g. metal ores, timber, grain). By integrating satellite IoT sensors across the work site, logistics managers can ensure fuel and raw material deliveries and product collections are planned according to site requirements, reducing bottlenecks and improving operational efficiency.

According to McKinsey and Company, operators which have more than 50% of their vehicle fleet connected to the internet have 23% better financial performance than peers with less than 50% connected. Companies with more than 75% of their fleet connected have 51% better financial performance.

3. Telematics

Monitoring heavy equipment on-site is integral to operational performance, and can also ensure the worksite is remaining committed to its safety, sustainability and environmental goals.

Aside from monitoring onboard sensors for predictive and reactive maintenance, telematics can also improve driver behavior, which in turn can reduce fuel consumption and carbon emissions. Heavy industry equipment by its nature burns fossil fuels and emits greenhouse gases during operation, but there are opportunities to limit these effects.

In the construction industry alone, machinery idle time averages 36% which increases fuel consumption by up to 5%. The biggest operational opportunity for reducing the potential for idling is ensuring vehicles are dispatched to their collection or drop-off locations according to requirements rather than on a continuous cycle, thereby preventing fleet waiting times.

There is also driver behavior to consider, with some operators leaving machinery idling during their break periods. Using real-time telematics, Site Managers can address the machinery operator actions immediately and encourage them to turn the machine off when not in use.

Through these two simple actions it is possible to reduce fuel costs, decrease carbon emissions, limit noise pollution and improve worksite air quality. When industry profit margins are challenging, evidence has shown that operators who lag behind their peers in reducing downtime are losing future business, wasting time and money, and increasing their ecological impact on the environment.

4. Theft Prevention

Heavy equipment theft costs the USA construction and agricultural industry an estimated $300 million to $1 billion annually, and is especially prevalent during the National Holidays of Labor Day, Memorial Day, Independence Day and Thanksgiving when worksites are closed and machinery is left unattended.

Satellite-connected video surveillance can enable real-time monitoring and recording of remote worksites and storage areas to protect both staff and equipment from unauthorized access.

Remote Video Surveillance Heavy Equipment

Heavy equipment can be fitted with discreet satellite asset trackers which can alert the operations team when equipment has moved out of a geofenced area or the machinery is being operated outside of normal worksite hours. Satellite assets trackers are especially effective at tracking stolen heavy machinery as they can keep connected across borders, and in the case of the Iridium network anywhere on Earth. Improvement in asset tracking capabilities has led to an increase in machinery recovery rates from 5% to 20% in the last 15 years.

5. Machine Learning and AI

Incorporating AI and machine learning capabilities into the mining, forestry, agriculture and construction industry has the potential to transform how these sectors address the challenges of CapEx and OpEx, as well as their environmental impacts. By leveraging data-driven analysis, businesses can optimize workforce and heavy machinery productivity, identify opportunities for fuel savings and emission reduction, limit raw material wastage and improve final product quality and volumes. Insights from these analyses can be replicated across multiple work site locations and integrated into cost projections for future projects, driving efficiency and sustainability.

6. Autonomous and Remote Control Heavy Machinery

One of the most significant challenges facing the mining, agriculture, construction, and forestry industries is an aging workforce, with many skilled workers nearing retirement and fewer new recruits stepping into these roles. Technological advancements in developing and implementing autonomous and remote operation of heavy equipment are helping to manage labor shortages while enhancing productivity and safety.

Autonomous Haulage Systems (AHS) are already in use across large-scale mining operations, enabling unmanned dump trucks to optimize hauling cycles, improve payload accuracy, and increase operational efficiency. However, not all scenarios are suitable for full automation, which is where remote control solutions come into play.

In hazardous environmental conditions or working on difficult or sloping terrain, controlling heavy machinery via remote control allows operators to manage equipment from a safe distance nearby or within a central operations hub. This minimizes risks to personnel while maintaining operational efficiency.

Both autonomous and remote-controlled systems rely on a continuous flow of real-time data, including video feeds and telemetry data, to ensure precise operation and avoid collisions. Satellite connectivity provides reliable and seamless data exchanges in remote locations, enabling the integration of automation and remote operation of heavy machinery in complex environments.

Satellite IoT Solutions for Heavy Machinery Monitoring

Satellite IoT is supporting innovation within the heavy machinery industry, addressing critical challenges such as remote connectivity, safety, and operational efficiency. By leveraging real-time data through predictive maintenance, telematics and remote monitoring, businesses can reduce costs, improve productivity, and meet stringent environmental goals. As automation and AI continue to transform the sector, embracing satellite-enabled solutions is essential for staying competitive in an increasingly connected world.

Get in Touch

Contact us to discover how our satellite IoT solutions can drive efficiency and profitability for your heavy machinery fleet.

With 20 years of experience, we can help you make the best choices based on your requirements.

Please call us on us on +44 (0) 1452 751940 (Europe, Asia, Africa, Oceania) or +1.805.783.4600 (North and South America); email hello@groundcontrol.com, or complete the form.

Small aviation operations—flight schools, tourist flights, and private fleets—often venture into areas where communication can be a challenge. Pilots need reliable tools to ensure safety, track their progress, and communicate effectively, even in remote regions. Yet, many still rely on cell phones or satellite phones for these critical tasks, despite their limitations.

Here’s why a dedicated satellite tracking device isn’t just a convenience—it’s a necessity that can save lives.

We asked 138 aviators who variously pilot helicopters (30%), gliders (18%), light aircraft (43%), cargo aircraft (25%) or military aircraft (15%) what, if anything, they were using to track their flights.

67% of respondents said they utilized the GPS on their cell phone; 34% had a satellite phone, and 33% had a dedicated satellite tracking device for this purpose (respondents were allowed to pick more than one answer).

While this didn’t come as a huge surprise, there are drawbacks of relying on cell phones. Coverage can be spotty, due to both the altitude and the remote locations visited, and also due to weather conditions. Cell phone service can be negatively affected by storms, wind, rain and even simply cloud cover (source).

Satellite phones are generally less affected by weather, and don’t suffer from coverage issues; they are, however, designed primarily for voice communication, and have none of the specialized features that pilots can benefit from with a dedicated aviation tracking solution.

We asked the same group what they valued most in a tracking solution, and, aggregating ‘essential’ and ‘nice to have’, the results were:

91% – Location alerts (moving in and out of geofences, stop/start etc.)
88% – Mission reports (e.g. mission ID, asset details, route, crew, cargo etc.)
87% – Real-time tracking
86% – Distress notifications and escalations
85% – Two-way messaging
83% – Electronic flight bag*

So there is widespread consensus of the value of aviation tracking, but as seen above, only a third of respondents had a dedicated solution for this.

*Advanced messaging including transmission of flight manifest, weight, balance etc.

Why Dedicated Satellite Tracking Devices Excel

Dedicated satellite tracking devices, like the RockAIR, are purpose-built for aviation. Here’s what sets them apart:

Aviation-Specific Features

Altitude Recording: Provides critical data unique to aviation, unlike general-purpose devices
Emergency Response: Distress notifications and escalation processes to ensure swift action when every second counts
Location Alerts: Track movement in and out of geofenced areas or detect when a plane has stopped unexpectedly.

Reliability in Critical Moments

Real-Time Tracking: Enables precise monitoring of flight paths, crucial for safety and coordination
Mission Reports: Record mission details such as route, crew, and cargo - helpful for operational efficiency and compliance
Two-Way Messaging: Communicate instantly, even in areas with no cell coverage.

Designed to Last

Long Battery Life: Far exceeds that of cell phones or satellite phones, ensuring uninterrupted service
Durability: Built to withstand extreme conditions, including potential crashes, ensuring operability when it’s needed most.

A Real-Life Lifesaving Story

The value of dedicated tracking devices isn’t theoretical—it’s proven. British pilot Sam Rutherford was flying in the Canadian wilderness when a crash left him stranded in freezing temperatures. Despite the dire situation, he managed to send a location-based message using his RockSTAR device. This timely communication enabled rescuers to locate and save him.

Without a dedicated satellite tracking device, Sam’s story might have ended very differently.

Key Use Cases in Small Aviation

Flight Schools

For flight schools, safety is paramount. Dedicated tracking devices allow instructors to monitor student pilots in real time, providing peace of mind and a critical safety net during training flights.

Tourist Flights

Scenic flights often traverse remote or rugged terrain. Real-time tracking and emergency features not only protect pilots but also reassure passengers of their safety.

Small Private Fleets

Fleet operators benefit from improved efficiency and safety with mission reports, real-time tracking, and emergency response capabilities, ensuring that every flight runs smoothly.

Why Not Cell Phones or Satellite Phones?

While cell phones and satellite phones play a role in communication, they fall short in critical ways:

	Cell Phones	Satellite Phones	Satellite Tracking Devices
Altitude Recording
Real-Time Tracking		*Some Models
Distress Notifications		*Some Models
Battery Life	Low	Medium	High
Durability	Low	Medium	High

Dedicated satellite tracking devices stand out as the only option that checks every box for aviation safety and reliability.

Flying with a dedicated satellite tracking device is more than a practical choice—it’s a lifesaving decision. From real-time tracking to emergency response, these devices are purpose-built to meet the demands of small aviation.

Can we help?

Don’t leave safety up in the air. Discover the RockSTAR, RockAIR, and other Ground Control solutions to ensure your operations are as safe and efficient as possible.

Contact us by completing the form, or emailing hello@groundcontrol.com; we’ll respond to your inquiry within one working day.

We’re excited to announce our strategic partnership with Locate Global, a prominent provider of incident management and workforce safety technology. This collaboration enhances workforce safety and incident response capabilities by integrating Ground Control’s high-speed satellite communication into Locate Global’s platform.

Locate Global’s platform enhances workforce safety and incident management through real-time location tracking, geofencing, and multi-channel communication tools.

It offers shake-triggered alerts, peer reporting, and immediate location data with video and audio to streamline emergency responses.

The system’s centralized dashboard also provides insights via heat maps and supports audit analysis, promoting a proactive safety culture.

The platform is designed for diverse applications, from protecting lone and remote workers to supporting global teams, with flexible integrations for any industry.

By incorporating Ground Control’s reliable satellite connectivity, Locate Global can provide consistent, secure communication even in remote or challenging environments where standard networks fall short.

“We are excited to partner with Ground Control, whose expertise in satellite communications complements our mission of ensuring safety and efficiency in the workplace. This partnership will allow us to provide our users with unparalleled connectivity, enabling them to communicate seamlessly and respond swiftly during emergencies.” – Raphael Polt, Head of Global Partnerships

RockSTAR is a handheld satellite device that provides global messaging and tracking in real time, designed for professionals working in remote or extreme locations.

It utilizes the Iridium satellite network, which is global and extremely reliable; as long as your team members have a view of the sky, they will be able to communicate with your base of operations.

RockSTAR features two-way messaging, an emergency alert button, hyper-accurate GPS tracking, and geofencing capabilities. It can be used instead of a cell phone, or linked via Bluetooth to allow usage of the Locate Global app.

The device is ruggedized for durability, waterproof, and has an extremely long battery life, making it viable for extended outdoor use.

Partnering with Locate Global aligns with our commitment to delivering robust communication solutions for industries where connectivity is paramount. Together, we are enhancing the ability for organizations to manage incidents effectively, ensuring that teams can maintain communication and safety in any environment.

Can we help you?

Our partnership with Locate Global empowers teams to communicate and respond effectively, even in the most remote environments.

If you’d like to know more, please complete the form, or email hello@groundcontrol.com.

As vital as wind energy is in reducing reliance on fossil fuels, it has created unintended challenges for wildlife, particularly bats. A 2021 survey found that 40% of people fear bats, though they play an essential role in pest control and pollination. By consuming insects, bats save U.S. agriculture billions of dollars in natural pest control each year, a service valued between 3.7 and 53 billion dollars. They also help pollinate crops like bananas, mangoes, and agaves (the central ingredient in tequila!), making them critical to both ecosystems and the economy.

Unfortunately, the growing number of wind turbines poses a real risk to bats. Tens, and possibly hundreds of thousands of bats are estimated to die each year due to wind turbines, with tree bats — species that migrate and roost in trees — being the most affected. These bats may confuse the towering structures with trees, bringing them dangerously close to the blades. While turbines can be temporarily slowed down to protect bats, this approach reduces the amount of clean energy produced, costing operators up to 3.5% of their annual output.

A more sustainable solution involves new technology that deters bats using ultrasound. Bats rely on echolocation to navigate, and the ultrasonic deterrent emits sound waves from the turbine that cause bats to alter their flight path, reducing collisions. The system monitors its own health to ensure reliability, and for remote locations, Satellite IoT transmits status data, ensuring operators can maintain its functionality, and demonstrate performance to regulatory authorities if needed.

Early results from this deterrent system show a 50-67% reduction in bat fatalities, with even greater results when combined with low-level curtailment. With continued innovation, wind farms can operate more harmoniously alongside bat populations, reducing wildlife impact while contributing to a greener energy future.

Enjoy our infographic, and please share to spread the word of this incredible innovation!

Infographic showing how technology is protecting bats from wind turbines

Can we help you with a remote IoT challenge?

We are specialists in remote connectivity. We work with several tried and trusted satellite network operators to deliver our customers with reliable, cost-effective solutions for communicating with your remote assets and sensors.

We’ve been doing this for more than 20 years, so if you’d like expert, impartial help with your IoT application, please email hello@groundcontrol.com, or complete the form.

Drones, or Unmanned Aerial Vehicles (UAVs), have become an integral part of modern military operations. Initially developed for reconnaissance and surveillance, drones have evolved into versatile platforms capable of executing various missions, from intelligence gathering to precision strikes. However, the full potential of UAVs is realized when enhanced with satellite connectivity, removing the limitations of traditional line-of-sight or terrestrial-based communication, and enabling real-time communication and coordination across vast distances and hostile environments.

While satellite connectivity has enhanced UAV capabilities, the utilization of UAVs in warfare is nothing especially new, and has instead, evolved significantly over the past century. Early concepts of UAVs emerged during World War I, with the development of rudimentary unmanned aircraft such as the “Kettering Bug,” – a drone prototype designed purely for bombing missions. However, these early models were not widely operational.

It wasn’t until World War II that UAV technology saw further development, particularly with the creation of the German V-1 flying bomb – essentially an early form of a cruise missile. The Cold War era spurred advancements in UAVs, primarily for reconnaissance purposes and the U.S. developed drones like the Ryan Firebee, which were used for surveillance during the Vietnam War.

The 1990s marked a turning point in UAV usage, particularly during the Gulf War, when drones like the RQ-2 Pioneer provided critical intelligence. Then in the early 2000s, UAVs like the MQ-1 Predator and MQ-9 Reaper – American remotely piloted aircrafts – gained worldwide attention for their role in counterterrorism operations. Powered by global satellite connectivity, these drones could carry out targeted strikes with high precision, far out of the reach of cellular and telecommunication networks. Step forward into 2024, and the role of UAV’s in modern warfare has only continued to advance. Let’s explore some of these key roles in more detail.

Key Roles of UAVs in Modern Warfare

Surveillance and Reconnaissance

Drones are extensively used for Intelligence, Surveillance, and Reconnaissance (ISR) missions. UAVs have the ability to capture real-time video and image data, which is transmitted back to command centers for analysis, without the need for soldiers to be physically present in hostile or rugged environments. The drones often operate at high altitudes, across multiple geographies.

Precision Strikes

UAVs equipped with precision-guided munitions allow military forces to carry out highly targeted strikes with minimal collateral damage. Their precision has made them instrumental in counter-terrorism operations and eliminating high-value targets while protecting civilian lives. Further, the remote strike action removes the need for ground forces.

Search and Rescue

In post-conflict or disaster scenarios, UAVs can locate survivors and assess damage in areas too dangerous or inaccessible for physical teams. This can prevent further human loss and lead to the identification, location and administration of aid to ground-based defense teams. Drones have also been know to guide troops to safe areas, and away from enemy fire.

Electronic Warfare

UAVs fitted with highly sophisticated sensor systems are designed to gather signals intelligence (SIGINT) by detecting and analyzing enemy radio transmissions, as well as electronic intelligence (ELINT) by monitoring radar emissions. This data can provide comprehensive insights into the structure, capabilities, and operations of enemy networks.

Aid and Supplies

UAVs can be adapted for resupply missions in hard-to-reach areas and have been deployed to help soldiers on the battlefield to receive essential supplies like food, water, and medical equipment. This capability becomes especially crucial in situations where ground convoys may face delays due to hostile terrain, enemy activity, or other logistical challenges.

Satellite Devices Best Suited for Military Drone Applications

Satellite connectivity is a reliable, secure means of communicating with UAVs far beyond the reach of terrestrial networks. These devices are our top picks for command and control, piloting BVLOS, and transmitting real-time video footage from UAVs.

Simple Command and Control with RockBLOCK 9603

Command and control of UAVs requires stable, low-latency communication channels.

RockBLOCK 9603 enables basic two-way communication over the Iridium satellite network, allowing operators to send flight commands or adjust mission parameters approximately once every 40 seconds, regardless of their geographical location.

For example, the RockBLOCK 9603 could send positional data, informing operators of any need to make altitude adjustments or course corrections during a mission. This level of sophisticated satellite-enabled command and control is essential for UAVs operating in areas where ground communication networks are compromised or unavailable.

RockBLOCK 9603 is especially suited to applications where space is at a premium. It’s designed to make adding Iridium Short Burst Data (SBD) satellite connectivity super easy.

Piloting Beyond Visual Line of Sight (BVLOS) with RockREMOTE Mini OEM

One of the most significant challenges in drone warfare is piloting UAVs beyond visual line of sight (BVLOS) – a necessity for long-range missions or operations in hostile areas.

Solutions like the RockREMOTE Mini OEM provide satellite-based connectivity designed for such operations involving on the move assets.

The RockREMOTE Mini OEM is lightweight, designed to draw as little power as possible, and harnesses the Iridium Certus 100 satellite network service, delivering virtually real-time IP connectivity.

This technology allows for piloting and navigation adjustments, crucial for UAVs conducting missions deep into enemy territory. Furthermore, satellite-based communication ensures the operator maintains constant control over the UAV’s flight path, even when thousands of kilometers away.

RockREMOTE-MIni-OEM-with-end-cap-transparent-background

Capturing Real-Time Video Footage with RockREMOTE Rugged

Arguably, one of the most critical functions of UAVs in modern warfare is real-time video reconnaissance.

RockREMOTE Rugged coupled with Videosoft video compression technology facilitates the transmission of high-definition video feeds from drones to ground stations, enabling military forces to monitor enemy activities and gather intelligence without delay. This helps military operators to respond to threats or gather information promptly, enhancing battlefield awareness and operational decision-making.

The RockREMOTE Rugged does not require antenna-pointing and even with a poor or changing view of the sky, the RockREMOTE Rugged can reliably and securely transfer data in close to real time via the Iridium satellite network.

Selecting the Right Satellite-Enabled Solution

	RockBLOCK 9603	RockREMOTE Mini OEM	RockREMOTE Rugged
Size	45 x 45 x 15 mm	175 x 60 x 37 mm	250 x 97 x 61 mm
Weight	36 g	287 g	1.2 kg
Power	Max 450mA	<30mW (sleep), <0.25W (idle), <7.5W (average transmit)	0W (sleep), 5W (idle), 9W (average transmit)
Satellite Service	Iridium Short Burst Data (340 bytes ↑ 270 bytes ↓ per message)	Iridium Certus 100 (22/88 Kbps) + IMT (100 kB per message)	Iridium Certus 100 (22/88 Kbps) + IMT (100 kB per message)
Interfaces	Molex PicoBlade 1.25mm pitch	Ethernet (available on pin out), Serial RS232, RS485, GPIO (2xI, 2xO)	Ethernet, Wi-Fi, Serial RS232, RS485
Antenna	Built in 1621 Mhz tuned patch antenna (or use optional SMA connector for external antenna)	External - various approved options	External - various approved options
Hosted Applications		Limited	Full
Ideal For:	Simple Commands / Failover Comms	Piloting BVLOS; Sending Compressed Images	Transmitting Real-Time Video Footage
	View Product	View Product	View Product

How IoT Satellite Connectivity Enhances UAV Capabilities

Enhanced Data Security

Satellite communication provides an additional layer of security for data transmission, which is fundamental for the defense sector. Satellite IoT can offer secure and encrypted communication channels that are less susceptible to cyber-attacks when compared to traditional terrestrial network options.

Reduces Risk to Life

When UAVs are remotely controlled and operated via satellite connectivity, missions can be conducted from secure, distant locations. This distance achieved by satellite coverage greatly minimizes the risk to human pilots and further reduces the need for ground troops to be present in high-risk zones.

Global Coverage

In many warfare scenarios, terrestrial infrastructure could be unstable, inaccessible or entirely absent. Satellite delivers reliable, continuous connectivity. This up-time reliability is essential when real-time data is needed for operational success, especially in critical warfare scenarios.

Scalability and Flexibility

Satellite IoT connectivity provides the ability to track and monitor multiple UAVs simultaneously without worrying about network congestion. In conflict zones when real-time communication is most critical, this ensures operators can adapt to varying mission requirements quickly and effectively.

The Future of Drones in Warfare

Enhanced mission control, achieving reliable global communication and minimizing risk to life via utilization of UAVs has already been well-demonstrated in modern warfare. Satellite connectivity-enabled drones have proven effective in conducting successful reconnaissance, military strikes and humanitarian aid missions worldwide.

The future deployment of UAVs in military operations only looks to increase with advancements in artificial intelligence (AI), swarming technology, and autonomous decision-making being key growth drivers. For instance, satellite-connected AI-powered drones, capable of identifying targets autonomously, making decisions in combat scenarios, and communicating with other drones, is already under development. It is also expected that the concept of drone swarms—where multiple UAVs work together to accomplish a mission—will likely play a significant role in future conflicts. All of these technological advances will require the reach and reliability of remote satellite connectivity to execute on a global scale.

In time, UAVs will also become more integrated with manned aircraft and other unmanned systems, creating a cohesive and very versatile military force. Whether it’s simple command and control, piloting BVLOS, or gathering real-time video for reconnaissance, the fusion of UAVs with satellite IoT is unlocking new possibilities for military operations globally, while minimizing the risk of collateral damage.

Can we help?

It’s an exciting time to be working on a remote IoT application, but with the greater volume of choice comes more uncertainty about the right service provider and networking technology for you.

We can help. We work with multiple satellite network operators with both standards-based and proprietary technology, and will provide you with unbiased, expert advice.

Complete the form or email hello@groundcontrol.com and we’ll get back to you within one working day.

Recently, the Swarm satellite constellation notified customers that, as of the end of 2024, they would no longer be able to utilize their service to communicate with their remote IoT sensors.

Swarm, purchased by Space X in 2021, is being sunsetted in favor of their new Direct to Cell (D2C) technology that Starlink – Space X’s satellite service provider brand – aims to bring to market in 2025.

But Starlink’s D2C technology isn’t a like-for-like replacement of the Swarm service. Swarm is/was (depending on when you read this!) a proprietary message-based service; you could send 192 bytes of data per message. It was designed for remote IoT deployments with power constraints – Swarm modems could be powered by a small battery or solar.

It also lent itself to applications where real-time communication was not required; as this blog post from 2022 illustrates, the average ‘round trip’ time for Swarm data delivery was 39 minutes and 44 seconds. Plus, Swarm utilized unlicensed terrestrial spectrum; this made it very low cost, but with the potential to have lower reliability in high-traffic areas.

Starlink’s D2C technology is an entirely different proposition. Firstly, it uses the LTE Cat-4, Cat-1, and Cat-1bis standards rather than proprietary technology. This delivers higher data rates and lower latency (the ‘round trip’ time) but has a greater power draw – not really suited to battery or solar-powered applications.

So, while Starlink are recommending to Swarm’s customers that they move to their D2C service once available – and this may well be a good choice – we thought it presented an opportunity to present additional options that may be a better fit for your application.

This is usually quite a nuanced conversation, and due to the blog post format, by necessity we’re making some simplifications. It’s always worth giving our team a call to get individualized, expert advice.

There are four key considerations: location, data rates, latency, and power.

1. Location

Starlink’s D2C service will initially be available in the USA, Canada, Australia, New Zealand, Japan, Switzerland, Chile and Peru (source). So, if your IoT application is not in one of these countries, you’ll need to look elsewhere.

For 100% global coverage, including the polar regions, have a look at Iridium which has the only truly global IoT network in operation. If your project is not in the far North or South of the globe, Viasat (pictured) is a great choice. Globalstar has great coverage over North and South America, China and most of Africa and Europe.

2. Data Rates

Here we’re not just considering how much data you need to send, but how you need to send it. The most efficient way to communicate with satellites is to use a message-based service, which is what Swarm offered. It’s cost-effective and uses very little power. However, it does generally require some engineering work on your part to manipulate your sensor data into this format.

If you have the ability to do this, check out the following services:

Iridium Messaging Transport (IMT), which allows you to send and receive 100,000 byte messages
Iridium Short Burst Data (SBD), which allows you to send a modest 340 bytes, and receive 270 bytes; constrained, but competitively priced
Viasat’s IoT Nano (previously called IsatData Pro), which allows you to send 6,400 byte messages, and receive 10,000 byte messages.

If you have a chatty application, and need to use IP data delivery, Starlink D2C is worth investigating (if/when available in your country / area of operation). Iridium Certus 100 is IP-based (22/88 Kbps), as is Viasat’s IoT Pro (formerly BGAN M2M). Because using IP data delivery is less efficient, it is often more expensive and power-hungry, so also explore whether your satellite IoT device supports edge computing, as this can help throttle back on airtime costs.

3. Latency

Latency refers to the length of time it takes for the data to leave the satellite IoT device, reach the satellite, come back down to the ground station, and be delivered to your server. One of the factors influencing this is the satellite orbit height; satellites in Low Earth Orbit (LEO) have a lower latency than satellites in Geostationary Orbit (GEO).

Latency for different satellite orbit heights diagram

That said, just because a satellite network is in LEO does not mean it will be quick to send and receive data, because the other factor is how frequently a satellite passes overhead. If your satellite network only has a handful of satellites in operation, it may be several hours, even a day, before your data is successfully transmitted. Swarm, despite having approximately 175 satellites in operation before it was disbanded, had big coverage gaps, which led to it having an average message delivery time of 39 minutes and 44 seconds.

This may not matter for your application. If you can manage taking receipt of your data a few times a day rather than in close to real-time, there are several new satellite networks that are worth investigating – among them Sateliot and OQ Technologies.

If you have a latency-sensitive application, an established satellite network in LEO is likely your best bet; Iridium or Starlink’s D2C service, for example. You could also experiment with changing timeout values on network requests to allow for higher latencies, caching more data, or using overlapping network requests and responses where possible (source). SD-WAN solutions can also be deployed to create hierarchical classes of service, and for TCP optimization (if TCP/IP is the preferred means of data delivery). This could unlock the GEO networks, such as Viasat, which are often more cost-effective than their LEO counterparts.

4. Power

Satellite connectivity is generally only the primary means of communication if there’s no cellular infrastructure in place – .e.g. oceans, deserts, mountains, forests and farmlands. Sensors deployed in these locations often also lack mains power, and are not easy to access.

For example: data buoys; hydrology stations; environmental monitoring; livestock monitoring; wind and solar farms and oil and gas pipelines.

In these instances, you need to look for solutions optimized for low power. Right now, that most likely means a message-based service using Iridium (IMT or SBD), Viasat (IoT Nano) or Globalstar’s satellite networks. In the next few years, Viasat and Iridium will start to offer standards-based solutions which will likely be lower cost, while still requiring very little power to operate. The great news is that proprietary technologies have started to come down in price in response to the advent of standards, so there’s no need to put your project on hold!

If your application has a power source – trucks, trains and heavy machinery, for example, or a remote outpost that has multiple solar panels – then you should take a look at Starlink’s D2C service, as it is expected to be competitively priced while moving (by IoT standards!) high volumes of data.

How to Choose

Choosing the best satellite network for your IoT application requires careful consideration of factors like location, data rates, latency, and power requirements. While Starlink’s D2C technology offers impressive data speeds and low latency, it may not be the ideal solution for all IoT deployments, especially those constrained by power or located outside the initial coverage areas.

Alternatives like Iridium, Viasat, and Globalstar provide various options, from message-based services ideal for low-power environments to IP-based solutions for higher data throughput. Ultimately, the right choice depends on your specific needs, and consulting with an expert can help ensure you pick the best network for your application.

Speak to an Expert

At Ground Control we’ve been solving remote connectivity challenges for over 20 years. We design and build our own hardware, and work with multiple satellite network operators and standards to ensure our customers get the right solution for their specific needs.

If you have an IoT or tracking application that’ll travel beyond cellular coverage, we’re happy to provide objective, expert advice. Email hello@groundcontrol.com or complete the form, and we’ll be in touch within one working day.