Lowering IoT TCO through smart manufacturing

When companies plan to deploy IoT devices, whether for industry, smart buildings, or logistics, they often focus on hardware pricing. That’s understandable; it’s the first number that stands out. But the purchase cost is just a small fraction of the Total Cost of Ownership (TCO). The real expenses lie in deployment, configuration, integration, management, and maintenance.

Think of buying a car. You’re not just paying for the vehicle. You also have to consider insurance, servicing, fuel, and potential repairs. The same goes for IoT. Costs tied to technical staff, software development or troubleshooting can quickly outweigh the device’s purchase price. The good news is that modern IoT manufacturers, such as ACRIOS, are designing solutions that reduce TCO from the ground up. Here’s how.

Preconfigured devices directly from the manufacturer

One of the most effective ways to reduce TCO is through ready-to-use devices delivered directly from the manufacturer. Instead of spending hours configuring each unit on site, the supplier can tailor the device in advance to meet your specific requirements. Key features of ready-to-use devices include:

• ‍Custom firmware installation: Devices come with software tailored to the project, e.g. a temperature sensor pre-set to send data at required intervals.
• ‍Parameter configuration: Communication protocols or data transmission frequency can be preloaded.
• ‍Active SIM cards: The device connects immediately to the network, no manual activation needed.
• ‍Pre-shipment testing: Every unit is verified before delivery to prevent installation issue.

Imagine receiving a sensor that works straight out of the box. No field configuration, no risk of human error. This saves time, reduces the load on your tech team, and accelerates deployment.

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Integration tools that save weeks of effort

Another cost-cutting benefit lies in software tools provided by the manufacturer. Instead of building everything from scratch, you can use ready-made solutions:

• ‍Sensor data processing  tools: These interpret raw sensor inputs and format them for easy integration into ERP systems, dashboards, or other applications.‍
• Containerised backend apps: Preconfigured Docker apps can be deployed in minutes – with no need to set up complex servers.

With these tools, onboarding a device can take days instead of weeks. That means fewer external developers, less time spent coding, and faster time-to-value.

Remote management for lower maintenance costs

Modern IoT devices don’t stop at installation. They include features that reduce ongoing maintenance and increase flexibility:

• ‍Over-the-air updates (FUOTA): Devices can receive firmware updates remotely. No need to send a technician on site.‍
• Remote configuration: Change settings like transmission intervals directly from the web interface.

These features save money on service calls, extend device lifetime, and allow quick adaptation to changing project needs.

Operational efficiency drives long-term savings

Manufacturers also help reduce TCO by building in features that optimise day-to-day operation:

• ‍Minimised data transmission: Devices send only essential data, saving bandwidth and mobile network costs.‍
• Battery life estimation: Algorithms predict battery replacement timelines, allowing for better planning and fewer disruptions.‍
• Precise battery health metrics: Using components like coulomb counters, some devices can report actual energy levels – not just voltage – making battery management much more accurate.

A full-stack solution for low-effort deployment

When combined, these elements form a complete solution covering the full lifecycle of IoT devices:

• ‍Preconfigured hardware  with SIM: Ready to use from the box.‍
• Software tools for integration: Simplify onboarding into your systems.‍
• Backend apps for data  analysis and control: Speed up time to value.‍
• Efficiency features: Lower operating and maintenance costs.

You don’t need to piece everything together – a quality supplier delivers a streamlined solution from start to finish.

Choose a partner who cares about TCO

Focusing only on the price of the hardware may seem cost-effective at first – but true savings come from considering the total cost of ownership. The right IoT supplier provides preconfigured devices, ready-to-use software, and lifecycle support that saves time, money and stress. Whether you need plug-and-play sensors, remote updates, or battery life optimisation, the right partner helps you deploy faster, smarter, and more cost-effectively.

FAQs about lowering TCO through smart IoT devices

How can I be sure that a preconfigured device will fit my project needs?

Reputable manufacturers offer custom configuration options during the ordering process. This includes firmware flashing, parameter setup, SIM card activation, and even field-specific calibration. If needed, most vendors can provide a pilot batch for testing in your real environment before large-scale deployment.

Is remote management reliable in the long term?

Yes. Modern devices support secure over-the-air firmware updates (FUOTA) and remote configuration, reducing the need for physical interventions and cutting maintenance costs.

How reliable is remote firmware updating (FUOTA)?

When implemented correctly, FUOTA is secure and robust. Updates are verified before installation, and manufacturers typically test updates under real-world conditions to ensure high reliability. This allows quick rollouts of fixes or improvements across your fleet.

Can data traffic be optimised to reduce costs?

Absolutely. Vendors often provide tools for data compression, threshold filtering, or event-driven transmission, all of which reduce traffic and prolong battery life.

How can I trust the battery lifespan estimates?

Battery prediction is based on real-world measurements and usage simulations. Advanced devices also include coulomb counters (not just voltage-based estimates), giving accurate insights into actual energy consumption and remaining capacity.

Do we need to build our own software for integration?

Not necessarily. Quality vendors offer backend apps or APIs that can be easily integrated with your existing systems. No need for custom development.

What if I use multiple suppliers or device types?

The best manufacturers support open protocols (e.g., MQTT, LoRaWAN, Modbus, etc.), so devices integrate easily into heterogeneous environments. Even in mixed fleets, unified data ingestion and visualisation is achievable with the right middleware.

Can I test the solution before full deployment?

Yes. Most vendors today offer pilot deployments so you can validate the benefits and functionality of the devices in a real-world setting before scaling up.

What happens if I need to change settings after deployment?

IoT devices from TCO-aware manufacturers support remote configuration. You can change reporting intervals, sensor thresholds, or network parameters over-the-air, without sending technicians into the field.

Want to reduce your IoT project costs? Whether you're planning a new deployment or optimising an existing one, we’re here to help. Let’s talk about how your project could benefit from lower TCO – without compromising on quality or flexibility. Get in touch

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