In Episode 183 of the IoT Use Case Podcast, host Ing. Madeleine Mickeleit speaks with Thomas Priebe from BESI Marine Systems GmbH and Thomas Hollasch from EXOR Deutschland GmbH. Together, they share insights into an IoT project in the maritime sector: It’s about energy-efficient pump control, condition monitoring, and CO₂ compliance – implemented using EXOR’s X Platform and JMobile software.
Episode 183 at a glance (and click):
Read the translation below:
Smart pump control, energy savings, and IMO compliance – with IoT on board
This episode explores how BESI Marine Systems GmbH, a specialized provider of automated flow management solutions for ships, teamed up with EXOR Deutschland GmbH to develop a data-driven Pump Energy Saving System (PES). The goal: reduce energy consumption and wear, while meeting international CO₂ regulations from the IMO (e.g., EEXI).
BESI is responsible for the system-level implementation – from pump and valve control to integration into the ship’s power grid. EXOR provides the IoT infrastructure via its X Platform: rugged panels, local data storage, and the JMobile software framework for visualization and data processing. The challenge: Relevant operating data must be captured securely and without manipulation under the strict security requirements of maritime systems – without direct cloud connectivity.
All data is stored locally on board and made available for analysis onshore. This enables documentation of operating conditions and transparent proof of energy savings. Looking ahead, condition monitoring features are also planned – so maintenance can shift from fixed schedules to a condition-based approach.
This episode offers real-world insights for decision-makers in maritime industries and mechanical engineering who want to implement IoT solutions under real operating conditions – with a focus on energy efficiency, data sovereignty, and pragmatic execution.
Tune in now to discover how true partnership-driven IoT projects succeed in the maritime world.
Hello, dear friends of IoT. Today’s guest is BESI Marine Systems from the maritime industry. This is especially exciting for me, because we haven’t covered this topic in this specific form on the podcast before. We often talk about the maritime sector in our community, but this specific use case is new. I’m really looking forward to this episode, because we’ll dive deep into the practical side and better understand how IoT is actually applied in this environment – especially considering the challenges of ship operations and possible solutions.
My guests today, who are here to share their best practices, are Thomas Priebe, Managing Director at BESI Marine Systems, and his IoT partner Thomas Hollasch from EXOR Germany. What exactly do they do? That’s what we’re going to find out now. As always, we’re interested in how such a project is actually implemented. What exactly was done? What are the use cases? How do you even access the data? And what are the key challenges to keep in mind when planning a similar project?
You’ll hear all of that in this episode. As always, more information can be found at www.iotusecase.com or in the show notes. Let’s head to the podcast studio.
A warm welcome again to both of you. Hi Thomas. And hi Thomas – I’ll have to be careful with the names today. I’ll just say “BESI Thomas” or “Thomas from BESI.” How are you doing today? You’re in Bremen, right? How was your week?
Thomas P
Yes, I’m in Bremen. We’re struggling with the elements here, just like you probably are, and we’re really wishing for some air conditioning. At the same time, we’re trying to handle our orders during the holiday season. There’s still quite a bit that needs to be delivered this summer. Luckily, we have a great team supporting us selflessly. We’re doing well.
That sounds fantastic. Where exactly are you located in Bremen, if I may ask? I just pulled up Google Maps.
Thomas P
We’re in Huchting, on the side heading toward Delmenhorst.
Got it. So not directly at the harbor, but at least not too far away.
Thomas P
There used to be a lot of shipyards here in Bremen, back when BESI was founded.
Shout-out to everyone tuning in from the region – and of course to all our other listeners as well. Thomas from EXOR, how are you? Where are you joining us from today?
Thomas H
I’m doing great, too. I just had three weeks of vacation and now I’m back at it. I’m probably sweating just as much as you are. I’m in my home office in Gießen – roughly between Hanover and Hildesheim. My office is under the roof, and it’s really hot right now, especially since I had to close all the windows and doors to block out background noise. Good thing podcasts don’t transmit smells.
Yes, very nice. Just to give everyone some context, we’re recording this episode in mid-August. I’m not sure exactly when it will go live, but I think it’s fair to say it’s been a beautiful summer. No reason to complain.
Thomas, let’s start with you and the BESI side. You’re a mechanical engineer and Managing Director of BESI Marine Systems GmbH. So, your background is primarily technical. We had already spoken briefly before this episode. You studied at TU Braunschweig and, if I’m not mistaken, you’ve been working in the industry for around 30 years now.
Thomas P
Yes, that’s right. I finished my degree in Braunschweig almost exactly 30 years ago. I studied flow and combustion engines – the institute no longer exists in that form, I believe. Back then, there were only three of us studying that major. Right after graduating, I started working at Behrens Pumpen – a company we still collaborate with today and with which I’ve built a strong connection over the years. I started out as a pump design engineer, but over time I got more and more involved in automation. Through several steps, I moved further into that field. And the maritime industry has always been my professional home.
Interesting – and greetings to my old hometown, by the way. I’m originally from Hanover and lived in Braunschweig for many years. I always enjoy finding these little connections. Let me ask you something more personal. You’ve spent decades working in pump technology and ship automation. What is it that fascinates you about maritime engineering? And what drives you to push forward with innovative projects like the Pump Energy Saving System? It’s not exactly a topic that everyone gets into – it’s a very specific world.
Thomas P
Well, when it comes to shipping – that would be a long story. My brother and I basically grew up with it. Our father was an inspector for a classification society and often spent weekends aboard ships. We got to go along and regularly visited ships in the Port of Hamburg. I think for any mechanical engineer, there’s something truly special about seeing a giant engine onboard a ship. It’s almost like a scene from Charlie Chaplin – these enormous machines turning once per second with this deep “wupp, wupp, wupp” sound. It’s just awe-inspiring. That’s how I got into shipping – and my brother as well, actually. We both ended up in the industry.
That’s so cool. And now you’re working on digitalization projects. How did that come about? Many people in the industry still say, “We don’t really need that.” What led you down that path?
Thomas P
Well, here’s the thing: our core products – take a valve control system, for example – can essentially be set up by any shipyard today. But the requirements our customers face are constantly evolving. And you grow along with those demands. To stay in the market, you basically have to reinvent yourself every few years. You always have to stay alert and sense where the market is heading. Part of that is intrinsic – because you enjoy developing new things. But at the same time, there’s also outside pressure that pushes you in new directions.
You mentioned your products earlier. BESI has been an established developer, manufacturer, and service provider for the maritime industry since 1966. You mentioned you’re based in Bremen, but you do a lot more than that. Could you walk us through what exactly you offer and who your customers are?
Thomas P
Our bread-and-butter products are flow management solutions for ships. Onboard, many different types of liquids need to be moved. There’s ballast water, for example, which must be pumped in and out depending on the ship’s load to ensure stability. Then there’s bilge water – water that enters the ship through rain or leaks – and that also has to be removed. Fuel needs to be transferred, as well as cooling water and cargo such as oil or chemicals. For all of these processes, we provide our customers with an all-in-one solution – from valve and pump control systems to specialized control valves.
We basically offer a complete worry-free package to our customers.
We manufacture many of the components ourselves – including actuators for valves, control cabinets, automation solutions, as well as the programming and customization. Everything comes from a single source. That’s our core business, and it’s what we’re known for.
Got it. And your customers – are they typically ship operators, shipyards, or who exactly do you work with?
Thomas P
Exactly. Our first point of contact during a new ship build is always the shipyard. That’s who we supply with our products. Further down the line, the project transitions to the ship operator – the shipping company. For them, we supply spare parts or develop new solutions tailored to current needs. In recent years, for example, exhaust gas cleaning systems have been retrofitted, which required the installation of additional pumps, valves, and pipelines. In such cases, the shipping company becomes our direct customer.
Understood. So you’re active in both service and maintenance as well as in technical equipment. And the topics we’re discussing today – like energy efficiency solutions – are also part of your portfolio now?
Thomas P
Exactly. That’s a new area we’re currently expanding. Especially through the partnership with Behrens Pumpen, who actively contributed to the work at BESI. The idea was to bring the pump into our product portfolio, so we can offer our customers a complete, integrated solution – from the pump to valve control to tank level measurement. All from a single source. We want to offer csystem-level technology, and that’s exactly what we’re now developing further in several directions.
You mentioned earlier that new requirements are coming in – from customers or the market. Could you explain in more detail what’s going on? Why are you now investing in digitalization and IoT? What changes are you observing specifically?
Thomas P
IoT is becoming relevant for us through the Pump Energy Saving System. It’s the first time we actually need to collect data directly from ships. In order to develop models for the cooling system, we first have to record the actual operating conditions. We need data on temperature levels, flow dynamics, cooling performance, and engine output. We first have to obtain this information so we can build our models based on it.
We are probably one of the few companies capable of replicating an entire cooling system on the Behrens Pumpen test bench. There, we can simulate on-board conditions and test our control systems under realistic conditions.
Thomas, I’d like to bring you in here to introduce you and EXOR a bit more. You’ve been working in sales and technical consulting for over 25 years, and since 2023 you’re responsible for Northern Germany at EXOR Deutschland GmbH. EXOR is also a partner in our network, and you offer an IoT platform – we’ll get into that in more detail in a moment.
Over the course of your career, you’ve surely seen a lot of technologies come and go. When you hear what BESI is working on right now – what excites you most about implementing IoT projects like this today? Was there a moment in your career when you thought, “This is exactly what I love doing – this is why I do this job”? You’ve been in the game for quite a while now.
Thomas H
Yes, that’s right, I’ve been doing this for quite a while. I studied electrical engineering the traditional way and found my way into automation through my thesis. Since 1997 I’ve been in technical sales, always focused on solution-based sales for various manufacturers. If I think back to my early days, there were countless classic PLC manufacturers back then – many of them don’t exist anymore. Over the years, traditional automation has continuously evolved toward IoT. The boundaries between OT and IT are increasingly blurred – today, there’s barely a clear line between them.
What fascinates me most is how all these new technologies – from AI to automated machine learning – have now become part of automation. Today, we rarely talk about classic control hardware or pure programming. We’re moving in completely new technological worlds, and that’s what excites me about this job: you’re always right at the cutting edge.
That’s exciting – especially at EXOR, your current company. You’ve been active in the classic HMI business for over 50 years, and now you’re going through your own transformation. We actually did a podcast episode with DENIOS recently – a very interesting one, by the way, on hazardous materials handling. I’ll link it in the show notes. There’s a lot happening at EXOR, too – you’re evolving with the market and implementing more and more future-ready IoT solutions.
Thomas H
Exactly, as you already mentioned, today we have our own IoT platform – we call it the X Platform. It’s essentially a modular system made up of hardware, software, and cloud solutions. With it, we can handle both traditional automation tasks like visualization and control, as well as the entire scope of remote services, all the way to a full-fledged digitalization platform.
How did this collaboration come about in the first place? Did the companies already know each other, or did you come across the project yourself? How did it all develop?
Thomas H
BESI has actually been a customer since around 2018, if my research is correct – so long before my time. When I joined EXOR, BESI was one of my clients from day one. It’s also worth knowing that BESI isn’t only based in Bremen – they also have a production site in Poland. I actually visited that site early on in my role, so I’ve gotten to know their technical team quite well. They, in turn, have a very direct line to our technical support department in Wuppertal. So overall, it’s a long-standing, collaborative customer relationship between BESI and EXOR. That made it a natural fit to take on this new project together – especially one that’s moving more into the IoT space.
So the joint project focuses on collecting data from ships and generating real value from it – probably both internally and for your customers. What exactly did you do there? What was the scope and the goal of the project?
Thomas P
The scope of the project – or one of the main challenges – was to gain access to the relevant data in the first place. That was a major hurdle. The project itself is part of a broader set of measures aimed at saving energy on ships, driven by the IMO – the International Maritime Organization. This organization sets the rules for the shipping industry and has committed to significantly reducing CO₂ emissions in the coming years. They give shipping companies very specific annual reduction targets, depending on the size of the vessel.
Okay, so CO₂ emissions are measured in grams per… how exactly is that calculated?
Thomas P
Grams of CO₂ per ton of cargo and per nautical mile. This is represented by an index called the EEXI – that stands for Energy Efficiency Existing Ship Index. This index has to be improved every year. The major reduction steps were already taken in the early years – for example through so-called derating measures, where engine output was capped. They also used new ballast systems, installed different propellers, and so on. Much of the potential has already been tapped. But until 2030 – and possibly beyond – shipping companies are still required to keep improving their EEXI index year by year.
That makes sense. When you consider that shipping accounts for two to three percent of global CO₂ emissions, it becomes clear where the pressure and regulations are coming from.
Thomas P
Exactly, driven by maritime shipping.
In Europe, a certificate trading system for ships has already been introduced. As far as I know, this system will eventually become obsolete once the IMO introduces globally uniform regulations. Once that happens, binding rules will apply to all ships worldwide. If those rules are not followed, shipowners may face financial penalties, or in extreme cases, ships might even be blocked from sailing until they comply.
Together with our sister company Behrens Pumpen, which manufactures pumps, we want to offer our customers a service that enables them to operate their pumps only at the level actually required. We achieve this by using frequency converters. This type of control technology is an area where we actively support shipping companies.
So the main driver really seems to be the regulatory environment. Are there any other aspects that make IoT relevant in this context? For example, improved operational transparency or predictive maintenance? You mentioned pump performance – is it only about compliance, or is there more to it?
Thomas P
No, the main focus is indeed on being able to prove the savings – to demonstrate them in concrete terms. And to do that, you need data. Either theoretical reference data or actual operating data from similar ships – both with and without the system. Only then can you transparently show the difference. It’s also essential for making predictions: You need real-world data to build a model, which can then be validated with test bench results or theoretical calculations.
Got it – that explains the background. I’m curious: are there technological challenges when it comes to data access? I imagine it’s not always easy for a shipyard or shipping company to hand over operational data to suppliers. Is that a straightforward topic, or something you have to work out together with the customer? What exactly is the challenge?
Thomas P
The biggest challenge is indeed gaining access to the data. Because of current cybersecurity requirements, ships today are essentially like fortresses. You don’t have open access to control systems. You can’t simply read them out, like you might be used to in other industries. Sure, there are security regulations there too, but on ships we’re dealing with what we call “mission-critical systems”.
Remote access to those systems is strictly prohibited. They must not be interfered with or compromised – because a system failure could cause major damage.
Right now, we’re collecting the data directly on our EXOR panels. Then the chief engineer or a crew member transfers the data to a USB stick and sends it to us via email. Of course, that’s a process with plenty of room for improvement.
Thomas, let me turn the question over to you and EXOR. You’ve likely encountered similar situations in other customer projects. What are the typical technical or operational hurdles you see? Not necessarily related to your products – but in general. Are these common issues, or very specific to each customer?
Thomas H
Cybersecurity is of course also a very important topic in industrial environments. In the past, automation systems were considered relatively isolated because they were mostly built on proprietary technologies. That has changed today. PC technologies have entered the field – and even though we use Linux instead of Microsoft on our systems, we still need to take careful precautions to prevent any external tampering.
Thomas P
Yes, in terms of security, we’re actually taking a few steps back with our products. Instead of relying on network-based solutions like Modbus TCP, we’re increasingly returning to serial interfaces. That ensures there’s no direct external connection. We also make sure the control panels are only accessible in supervised areas. Just by physically placing these panels in restricted spaces, we avoid uncontrolled access to the Ethernet. That’s a deliberate step back.
Let’s assume we have a specific pump – how exactly is the data collected? And how is it transferred, especially considering the ship is out at sea? What’s your concrete approach here?
Thomas P
On board the vessels, we use our own control system to regulate pump operation via frequency converters. All process data, as well as control and monitoring data, flows into our PLC, which then provides this data to the EXOR panel for storage.
We gather external data exclusively via serial interfaces – Modbus RTU or NMEA – and route that data into the PLC as well, which then passes it to the EXOR panel. On the panel, we use the built-in tools to store the data locally.
The process works like this: the stored data is exported by the chief engineer onto a USB stick, zipped into a file, and emailed to us. That’s how we currently receive the data. It’s a very practical approach for us, and easy to operate.
This is all new territory for us – we’ve never logged data before, and we’ve never had to actively access ship data. But with the tools, especially JMobile, it’s been working very well. Our employees were trained accordingly and were able to read out the data without any issues.
At the moment, we’re still in the phase of collecting baseline data, which will be used by the University of Bremen to build models. So far, it’s all running smoothly.
We just heard the term JMobile – some listeners might be familiar with it. Thomas from EXOR, could you explain what JMobile actually is and how it handles the data?
Thomas H
As I mentioned earlier, our X Platform is made up of several components – and JMobile is one of the key ones. It’s our self-developed IoT software that runs on all of our devices. Originally, JMobile started out as a visualization tool, but over the years it has evolved significantly. Today, the focus is clearly on data handling, which is why we now refer to it as IoT software.
JMobile offers very high connectivity. It supports more than 200 device drivers to connect to classic PLC or SCADA systems, as well as modern protocols like OPC UA and MQTT for communication with cloud systems. So, communication and data handling are at the core. JMobile also includes a built-in database where data can be stored with timestamps and exported, for example, as a CSV file.
This is exactly how BESI is using it in their project – storing the data locally on the device and exporting it via USB stick for further processing. That might sound a bit old-fashioned, but in this specific application, a direct cloud connection isn’t possible for security reasons.
This has nothing to do with the size or type of customer. In other projects – like the one we did with DENIOS, where we covered hazardous material handling and tank monitoring – the requirements were different. Here, we’re dealing with a highly sensitive maritime environment. Every customer has unique needs, so it’s a big advantage that EXOR provides an open platform. That allows us to integrate various control systems, sensors, and devices – depending on the use case.
How exactly does the data handling work – especially the transition from OT to IT? You said JMobile plays a central role here. What does that process look like in practice? Is everything handled directly within JMobile, or do you also use additional applications tailored to each use case?
Thomas H
Essentially, everything can be handled directly within JMobile – either using predefined libraries or templates. But users can also add their own functionality. For example, you can integrate JavaScript. The system is designed to be open, so you can even deploy your own applications at the Linux level. We support Docker technology, which means if customers already have programs that run in a Docker container on Linux, we can also run those on our devices. So JMobile doesn’t have to operate in isolation – it can work in combination with other programs and tools, although in practice that’s often not even necessary.
And for you, Thomas – is this more like a white-label solution? So, does JMobile at BESI show your own logo, and do you see pump performance data there, for example? Can you use that to directly prove the savings? Or how exactly do you use JMobile in the final setup?
Thomas P
We import the data we receive into our systems and then look at the graphs, summing up specific time periods. We sometimes use our own software for that, and I believe the IAT – that’s the Institute at the University of Bremen – uses tools like MATLAB or similar solutions. The CSV files can be read in just about anywhere.
Personally, Excel is still the easiest option for me. We log data at one-minute intervals, and Excel handles that well. Especially when I want to present something clearly to a customer – in the form of charts, for example – it’s the simplest solution for me. I’ve worked with specialized tools like EMC before, but there are plenty of options depending on the requirements.
So you can visualize the data for your customers – and that’s exactly what you need to bring your use case to life. That ties it all back together.
Thomas P
Exactly.
Very nice. I often get asked whether there are specific best practices or lessons learned – things you would recommend to others who are starting similar projects. Are there any pitfalls or tips you’d share with the community?
Thomas H
When I work with machine builders, I always give the same advice: Find a partner who doesn’t just sell you components, but who works with you as a true collaborator. Someone who develops the solution together with you. That’s how you overcome major hurdles. It’s all about working together – not just a classic supplier-customer relationship, but a real partnership in solution development.
EXOR’s motto is: Your Challenge, Your Solution, Our Technology. We see ourselves as IoT enablers. We provide our customers with the tools they need to solve their challenges. The implementation is of course in their hands, but we support them – as a partner, not just a vendor. And with that mindset, we’ve delivered a wide range of solutions – in industry, marine automation, and building automation. With the right setup, every challenge can be tackled.
Thomas P
As a medium-sized company, a development project like this is a real challenge – especially since we don’t have our own development engineers in-house. Everything happens alongside the day-to-day business. That’s why we’re completely reliant on collaboration with our partners and suppliers.
In this project, we’ve had EXOR by our side, the manufacturer of the frequency inverter, and the university. Without these partners, many things simply wouldn’t be possible for us. We just don’t have the capacity to dig into every detail ourselves. We need partners who are willing to take initiative and come back to us with practical, viable solutions. That’s critical for us. With EXOR, it works extremely well – especially because there’s a close personal relationship, particularly with the automation team in Poland. That makes collaboration very smooth and effective.
I think a lot of people out there feel the same way – especially smaller companies. You really need a partner at eye level who develops solutions with you. If that sounds familiar, feel free to get in touch.
I’ll include the contact details for both Thomases and some additional links in the show notes. Whether you’re interested in this specific project, want to share your own best practices, or face similar challenges – whether with pumps or completely different machines or systems – you’ll find great options at EXOR. Just connect and start the conversation.
Thomas H
Absolutely.
And it’s always worth checking out our platform – you’ll find plenty of similar real-world projects there. I think that helps many who are currently on their way into the world of IoT.
Are there any future plans on your end? Will the project be expanded further? Or are there any upcoming developments around EXOR’s X Platform that you can already share with us as a sneak peek? What can we look forward to?
Thomas H
Yes, the X Platform is constantly evolving. I think today’s conversation made it clear that we’re becoming more and more of a comprehensive IoT solutions provider. That includes continuously expanding our hardware offering – for example, our own industrial PCs and panel PCs, a wide range of mobile panels, IoT gateways, and edge devices. So, the hardware side is growing significantly.
At the same time, we’re also pushing our digitalization platform forward. There will be a dedicated marketplace in the future. Virtual reality is also on our roadmap – along with integrating AI into our devices. In the future, AI algorithms will run directly on an HMI, recognizing user interactions and triggering actions automatically. That’s the direction we’re actively developing toward.
We’re also integrating our own IEC 61131-3-compatible PLC directly into JMobile. That means JMobile will play a central role not only for visualization, but also as a key part of our overall solution portfolio.
And what about your side, Thomas – how are things moving forward at BESI? Can you already share what’s next for the project?
Thomas P
Looking ahead, we’re planning to expand what we internally call PES 4.0 – the next stage of our Pump Energy Saving System. Our goal is to integrate condition monitoring directly into the PES. That would not only enhance energy savings but also bring clear benefits for wear and tear management. When pumps run at lower speeds, wear is significantly reduced. So in the long run, we might no longer need to follow rigid maintenance cycles or replace bearings on schedule.
Instead, we could move towards a truly condition-based maintenance approach. And since pretty much every pump today is connected to automation systems in some way, we already have the data we need. It’s just a matter of evaluating that data properly. That also increases the need to make these insights available onshore – so shipping companies, for example, can get early warnings like: “This pump is showing irregular behavior – we’ll need to act soon.”
A great look ahead – maybe we’ll catch up again in a year or two for an update on how the project evolved.
From my side, thank you so much for the conversation.
It was great to hear such a practical perspective on the challenges – both technical and regulatory. Cybersecurity of course played a big role too. Thank you both for taking the time to join us on the podcast. I’ll hand over to you for the final word – whether it’s a quick thank you or however you’d like to close the session.
Thomas P
Thanks a lot! It was really fun – and who knows, maybe there’ll be a next time. I’d definitely be up for it.
Thomas H
Thanks also from my side for the invitation and the great hosting. I’m almost a regular now – this was my second episode. Last time I promised you I’d bring a project from the maritime world – and here we are. Maybe the third one will be about building automation – we’ll see. Either way, I’m really looking forward to continuing the collaboration.
Wonderful. Thanks again to both of you – and have a great rest of the week. Take care. Bye!
Thomas P
Thank you!
Thomas H
Thanks – you too. Bye!