About Acoustic Cameras
Acoustic cameras are highly effective diagnostic tools designed to reduce excessive utility costs, avoid equipment breakdowns, and minimise operational downtime across various industries. These advanced devices use a combination of multiple sensitive microphones and powerful imaging software to “see” sound, allowing technicians to visually identify the source of issues such as compressed air leaks, partial discharge, or faulty mechanical components.
- Detect pressurised leaks in compressed air systems up to 10 times faster than traditional leak detection methods
- Pinpoint partial discharge (PD) or corona with precision in high-voltage systems
- Find mechanical anomalies like faulty bearings or steam trap failures using sound mapping
Why Microphones Matter
The Power of More Microphones
The number of microphones in an acoustic camera directly impacts how accurately and effectively it can detect sound. A single microphone captures both the desired sound (signal) and some background interference (noise). By increasing the number of microphones, the device significantly improves its signal-to-noise ratio. This means more relevant sound data is captured while background noise is reduced, making it easier to detect smaller leaks and subtle mechanical issues in real time.
Improved Detection Range
A higher microphone count doesn’t just improve clarity—it also extends the camera’s detection range. For example, quadrupling the number of microphones roughly doubles the distance from which a sound can be detected. This means maintenance teams can spot issues from further away, improving safety, speed, and accuracy. Long-range sound detection also enables routine inspections without needing to interrupt production or physically access difficult or hazardous areas.
Smart Microphone Placement
Microphone arrangement is just as important as microphone quantity. In acoustic cameras, microphones are grouped in strategic patterns, often circular or spiral arrays, to allow for precise directional sensitivity. This configuration helps triangulate the exact origin of a sound. With this directional accuracy, technicians can easily distinguish between multiple sound sources and isolate the true problem—whether it’s a leaking valve, a cracked connector, or a failing electrical component.
Who Can Benefit from Acoustic Cameras?
(Functionality may vary by model)
Pulp & Paper Industry
Energy expenses in pulp and paper manufacturing can represent up to 20% of total operating costs. Compressed air systems are commonly used in these facilities, but they are prone to leaks—especially in older infrastructure. These leaks result in wasted energy, reduced operational efficiency, and increased costs. Acoustic cameras enable fast and reliable detection of pressurised air losses, helping operators make timely repairs and keep systems running efficiently, all while contributing to sustainability goals.
Food & Beverage Industry
In the food and beverage sector, compressed air powers automation, cleaning, packaging, and more. Air leaks can compromise product safety, contaminate food through backflow, and reduce line efficiency. As facilities become larger and more complex, pinpointing the exact location of a leak by ear becomes impractical. Acoustic cameras overcome this by providing visual confirmation, even in noisy, high-traffic environments. They are an essential part of predictive maintenance and quality control strategies.
Automotive Industry
Automotive manufacturing uses compressed air extensively for tasks like stamping, painting, welding, and robotics. Systems often operate 24/7 and must be highly reliable. Any leak or failure can halt production or degrade output quality. Because facilities are generally loud, traditional ultrasonic tools may not be effective. Acoustic cameras cut through the noise and offer accurate, real-time fault detection across multiple applications. They also help reduce compressed air waste, which can translate into significant annual savings.
Mining Industry
Mining operations depend on compressed air to drive drills, control ventilation, and support safety systems in both open-pit and underground environments. These are high-risk areas where system failure can endanger workers and affect output. Leaks in compressed air systems raise operating costs and reduce overall efficiency. Acoustic cameras offer a proactive maintenance solution, capable of identifying air leaks and mechanical faults even in dusty, hazardous, or remote areas—without shutting down operations.
Manufacturing
Tire Manufacturing: In tire production, nitrogen and steam are used under high pressure during the curing phase—steam at 8 bar and nitrogen at 24 bar. Any reduction in pressure compromises product quality, resulting in rejected tires and increased waste. These rejected units also require recycling, adding even more cost. Acoustic cameras provide early detection of pressure leaks, ensuring only high-quality tires move forward in production, reducing material loss and improving profitability.
Cement Manufacturing: In cement plants, production temperatures can reach as high as 2000°C. Over time, this intense heat can warp equipment, leading to hard-to-detect leaks that reduce thermal efficiency and increase fuel use. Acoustic cameras help spot those issues early—keeping fuel costs down, maintaining consistent kiln temperatures, and reducing the likelihood of equipment failure. Their use supports both performance and environmental targets.
Book a demonstration today to see how acoustic cameras can reduce maintenance costs and improve production efficiency in your facility.
Utilities Sector
Utility companies use acoustic cameras to detect partial discharge (PD), a telltale sign of insulation deterioration in high-voltage equipment. PD detection is critical because these faults can evolve into equipment breakdowns, fires, or system-wide outages. Historically, PD inspections required bulky equipment and expert interpretation, often limiting how frequently tests were performed. Acoustic imaging changes that.
With acoustic cameras, utility engineers can visually locate PD in real-time—even in outdoor substations or at heights—without physical contact. The intuitive interface makes it easier for technicians of any skill level to use. This leads to more frequent and consistent monitoring, which reduces the chance of unexpected failures. Acoustic imaging makes maintenance safer, faster, and more cost-effective.
Whether for transmission lines, switchgear, transformers, or rotating machinery, acoustic cameras give utilities a reliable, first-warning tool to help protect infrastructure, reduce costs, and improve system resilience.
If you have any questions, contact our friendly team today — we’re here to help you explore the right acoustic camera for your business needs.