Amcor’s New London Healthcare plant operates 24/7, supporting healthcare-focused manufacturing that depends on stable airflow, protected systems, and reliable preventive maintenance. To gain better visibility into HVAC performance and other critical assets—without the cost and complexity of expanding a traditional building automation system—Amcor partnered with Bassett Mechanical to implement Bassett4Sight.

Rather than addressing a single challenge, Bassett4Sight has evolved into a multi-purpose monitoring platform for differential pressure, temperature, and vibration. The result is a more data-driven, proactive maintenance approach that helps the facility anticipate issues before they escalate.

The Challenge

The facilities team at Amcor’s New London plant is responsible for maintaining:

• Consistent airflow and pressure relationships
• Protected systems that support healthcare manufacturing
• Reliable equipment operation in a 24/7 environment

Historically, many issues were identified only after performance began to decline—such as rising differential pressure, temperatures dropping below safe levels, or early signs of mechanical failure. While the plant uses a building automation system (Carrier i‑Vu) in select areas, expanding that system across the facility would require a significant capital investment.

Seasonal conditions added further complexity. Cottonwood and frost can restrict airflow at intake screens, increasing differential pressure and creating downstream risks. If left unnoticed, these conditions can lead to collapsed HEPA filters, unfiltered air entering the facility, unit shutdowns, and potential impacts to pressurization and product quality.

Prior to Bassett4Sight, technicians relied heavily on manual inspections, often reacting only after problems had already escalated.

To move forward, Amcor needed a solution that could:

• Identify problems early
• Automatically alert the right people
• Scale over time as needs evolve
• Remain flexible and cost-effective

The Solution: Bassett4Sight

Bassett4Sight was implemented as a standalone monitoring platform that complements existing systems while filling critical visibility gaps. The system was brought online in less than two months and expanded incrementally as value became clear.

Key elements of the solution include:

• Differential pressure monitoring
• Temperature monitoring in critical spaces
• Vibration monitoring for rotating equipment
• Centralized alerts accessible by desktop and mobile

Key Applications for Amcor

Differential Pressure Monitoring

Differential pressure sensors were installed on HVAC equipment to provide continuous insight into airflow performance. Instead of relying on periodic physical checks, the system monitors trends in real time and issues alerts when pressure moves outside acceptable ranges.

This visibility enables the facilities team to identify restrictions early, prevent downstream issues such as filter damage or airflow imbalance, and respond consistently across all shifts. As Facility Engineering Manager Timothy Gess explains, the biggest difference is the ability to act sooner, anticipating issues instead of reacting after something goes wrong.

Temperature Monitoring

One of the most critical expansions of Bassett4Sight involved adding temperature sensors in the fire pump house, a space located outside the main building envelope.

Previously, temperature monitoring in this area was visual and local, meaning a freeze-related issue might only be discovered after damage had already occurred. With Bassett4Sight in place, temperatures are now monitored remotely, alerts are triggered as readings approach unsafe thresholds, and notifications are shared across the entire team.

This added visibility protects a mission-critical life safety system without the need for constant physical checks. Gess notes that the system now provides early warning if temperatures drop below a set threshold, allowing the team to respond before freezing becomes a risk.

Vibration Monitoring

Amcor is also evaluating Bassett4Sight’s vibration monitoring capabilities alongside an existing third-party system. The facility currently uses a costly, sensor-heavy vibration platform and is assessing whether Bassett4Sight can deliver comparable insights using a more targeted, cost-effective approach.

Bassett4Sight vibration monitoring:

• Tracks frequency-based vibration changes
• Alerts the team when measurements move outside normal parameters
• Helps identify early signs of bearing wear or mechanical failure

The long-term strategy is to focus monitoring on critical assets, expanding coverage only where it provides meaningful value.

How the Team Uses Bassett4Sight

Centralized Alerts & Accessibility

Bassett4Sight brings multiple data streams into a single platform accessible from a laptop or mobile device. Gess says, “accessibility is key—the system allows us to quickly check conditions, but more importantly, it notifies the team when action is needed.” With alerts pushed automatically, the risk of issues going unnoticed is significantly reduced.

A Culture of Preventive Maintenance

With Bassett4Sight in place, the facilities team has shifted from reactive responses to a more proactive maintenance strategy. The system supports:

• Proactively scheduled maintenance
• Fewer emergency repairs
• Greater trust in data-driven alerts

Over time, alert thresholds can be refined to reduce nuisance notifications and ensure attention is focused on issues that truly require action.

Results & Value

While Amcor has not assigned a formal ROI, the operational benefits are clear:

• Improved protection of critical systems
• Reduced unplanned maintenance events
• Better decision-making through real-time data
• Less reliance on manual inspections
• Greater peace of mind for a lean facilities team

As Gess puts it, the value lies in combining data interpretation with timely warnings, allowing the team to stay ahead of problems rather than respond after the fact.

Scalability & Future Vision

Bassett4Sight is a foundational platform, not a fixed solution. The facility is already gaining value today, while knowing the system can continue to grow.

Future possibilities include:

• Expanding vibration monitoring plant-wide
• Adding temperature sensors in other critical areas
• Integrating additional asset data into a single, centralized view

“Bassett4Sight is a building-block system, one that delivers value now and provides flexibility for whatever comes next, says Gess.

Partnering with Bassett Mechanical

Amcor’s long-standing relationship with Bassett Mechanical played a key role in the success of Bassett4Sight. Collaboration across technicians, program management, and back-office teams helped ensure a smooth rollout and ongoing support.

For the New London plant, this partnership has enabled Bassett4Sight to evolve alongside facility needs, supporting preventive maintenance, asset protection, and confident decision-making. It has become more than a monitoring tool; it’s a strategic platform helping the team move from reactive maintenance to proactive facility management, one alert at a time.

Interested in expanding visibility across critical building systems?

Bassett4Sight supports proactive, data-driven facility management without the cost and complexity of traditional solutions.

Contact us today!