Rust Mote Inc. delivers end-to-end industrial IoT consulting and system integration services — transforming factory floors and infrastructure into intelligent, data-driven operations.
Founded in California's Central Valley, Rust Mote Inc. brings together industrial engineers, software architects, and data scientists with a shared passion for making operations smarter.
From our base in Tipton, CA, we serve clients across the Western United States — from food processing facilities to energy infrastructure in the Sierra Nevada foothills.
Six integrated service lines covering every dimension of your industrial digital transformation.
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Service 01
IoT Strategy & Consulting
Before deploying a single sensor, we work with your leadership and operations teams to define a clear, ROI-driven roadmap. Our consultants bring deep industrial domain expertise across manufacturing, energy, agriculture, and logistics.
We assess your current OT landscape, identify the highest-value automation opportunities, and define a phased implementation plan that minimizes disruption to production.
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Current-state OT/IT infrastructure assessment
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ROI modeling and business case development
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Technology vendor selection and architecture review
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Phased digital transformation roadmap
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Change management and workforce planning
Typical Assessment Findings
Data Visibility Gap73%
Manual Reporting61%
Legacy Protocols85%
Reactive Maintenance68%
Avg. ROI Potential3.2×
Typical Payback14 months
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Service 02
System Integration
Connecting diverse industrial equipment, sensors, PLCs, SCADA systems, MES, and ERP platforms is our core competency. We are protocol-agnostic and work across every major industrial standard.
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OPC-UA, Modbus, DNP3, PROFINET, EtherNet/IP
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MQTT / AMQP message broker configuration
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ERP/MES integration (SAP, Oracle, Infor)
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Legacy equipment retrofit with modern gateways
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API development and data normalization
Integration Layer — Live Status
🏭 PLC → Gateway● Connected
📡 MQTT Broker● 1,248 devices
☁️ Cloud Sync● 12ms latency
📊 ERP Connector● Real-time
🔔 Alert Engine⚠ 3 Active
Data Pipeline Reliability99.7%
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Service 03
Edge Computing
Not all data needs to travel to the cloud. Our edge computing solutions enable real-time processing at the source — reducing bandwidth, lowering latency to milliseconds, and enabling operations even during network outages.
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Edge hardware selection, hardening, and deployment
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Containerized workloads (Docker / Kubernetes)
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Local AI/ML model inference at the machine level
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Offline-capable operations with cloud sync
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Over-the-air (OTA) firmware updates
Edge Node — Performance
Processing Latency4ms
Bandwidth Saved87%
Offline Resilience72 hrs
Model Accuracy96.2%
CPU Utilization42%
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Service 04
Data Analytics & AI
Our data science team transforms raw sensor streams into actionable intelligence — from real-time dashboards to predictive models that anticipate failures weeks in advance.
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Time-series analytics with InfluxDB / TimescaleDB
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Custom Grafana dashboards and KPI reporting
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Predictive maintenance ML models
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Anomaly detection and early-warning alerting
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OEE optimization and yield improvement analytics
Predictive Maintenance — Alert Queue
🔴 Conveyor Belt #3 — Bearing7 days
🟡 Pump Station B — Cavitation14 days
🟢 Chiller Unit AOK
🟢 Compressor #1OK
Model Precision94.8%
Avg. Lead Time11 days
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Service 05
OT/IT Security
Industrial control systems are increasingly targeted by sophisticated cyber threats. Our security practice is built around IEC 62443 standards, with deep expertise in OT network segmentation and zero-trust principles.
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IEC 62443 compliance assessment and implementation
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OT network segmentation and DMZ architecture
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Device identity and certificate management
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Continuous OT network monitoring (SIEM)
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Incident response planning and tabletop exercises
Security Posture Dashboard
Network Segmentation✓ Enforced
Device Auth (Certs)✓ All 1,248
Firmware Patched97.2%
Anomalous Traffic2 events
IEC 62443 ScoreSL 2.4
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Service 06
Managed Services
After deployment, your IIoT platform needs ongoing care. Our managed services team becomes an extension of your operations staff, providing 24/7 coverage without the overhead of building an in-house team.
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24/7 infrastructure monitoring and alerting
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Proactive maintenance and OTA updates
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SLA-backed response times (4hr / 8hr / NBD)
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Monthly performance reports and QBRs
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Continuous improvement recommendations
Managed Service — SLA Dashboard
Platform Uptime (30d)99.94%
Tickets Resolved142 / 143
Avg. Response Time18 min
CSAT Score4.9 / 5
SLA Compliance100%
FAQ
Frequently Asked Questions
How long does a typical project take?
A pilot deployment for a single production line typically takes 6–10 weeks. Full-facility integrations range from 4–12 months depending on scope, equipment age, and complexity.
Can you work with our existing equipment?
Yes — we specialize in brownfield deployments. We retrofit equipment from the 1980s through today using industrial gateways and protocol converters.
Will integration disrupt our production?
We design deployments to minimize production impact through phased rollouts, off-shift installation windows, and parallel system validation. Most clients report zero unplanned downtime.
What cloud platforms do you support?
We are cloud-agnostic: AWS IoT, Azure IoT Hub, Google Cloud IoT, and private cloud. We help clients select the platform that best fits their existing infrastructure and cost model.
Do you offer fixed-price projects?
Yes. After a scoping assessment, we offer fixed-price contracts for well-defined integration projects. We also offer time-and-materials for complex, evolving engagements.
Where do you operate?
Our headquarters is in Tipton, CA. We serve clients throughout the Western United States and support remote/hybrid projects nationally for the right engagements.
Ready to start your IIoT journey?
Our engineers are based in California's Central Valley and ready to assess your facility.
Home / Industries
Built for Every Industrial Sector
Specialized domain knowledge across six major industries — understanding the unique protocols, regulations, and operational challenges of each environment.
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Manufacturing
Smart Factory & Discrete Manufacturing
Manufacturing operations face constant pressure to increase throughput, reduce defects, and minimize downtime — all while controlling costs. IIoT is the enabling technology that makes Industry 4.0 a reality on your floor.
Core Challenge
Unplanned downtime costs manufacturers an average of $260,000 per hour. Manual OEE tracking and reactive maintenance leave significant value on the table.
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Real-time OEE monitoring across all production lines
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Predictive maintenance with 10+ day advance warning
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Computer vision quality control and defect detection
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MES / ERP integration for closed-loop production control
Manufacturing IIoT — Impact Metrics
34%
Average Downtime Reduction
Achieved through predictive maintenance across our manufacturing clients
18%
OEE Improvement
Typical uplift within 12 months of real-time monitoring
$1.2M
Average Annual Savings
Per facility across maintenance, energy, and quality costs
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Energy & Utilities
Power Generation, Transmission & Distribution
The energy sector is undergoing its most significant transformation in a century — integrating renewables, managing distributed assets, and adapting aging infrastructure to meet modern demands.
Core Challenge
Grid operators managing thousands of distributed assets across hundreds of miles face visibility gaps, latency in fault detection, and regulatory compliance burdens that strain engineering teams.
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Remote substation and generation asset monitoring
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Renewable energy integration and forecasting
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SCADA modernization with cybersecurity by design
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NERC CIP / FERC compliance documentation
Energy & Utilities — Impact
60%
Reduction in Field Visits
Remote diagnostics replace most routine site inspections
99.4%
System Uptime Achieved
Across remote pump station networks in Central California
12min
Average Fault Detection Time
Down from 4+ hours with manual monitoring
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Oil & Gas
Upstream, Midstream & Downstream Operations
Oil and gas operations span vast geographies with safety-critical systems that require real-time visibility, fail-safe controls, and rigorous environmental monitoring.
Core Challenge
Aging field instrumentation, limited connectivity in remote locations, and strict environmental regulations create a complex digital transformation landscape requiring specialized engineering expertise.
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Wellhead automation and remote monitoring (SCADA)
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Pipeline integrity monitoring and leak detection
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Emissions monitoring and environmental compliance
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Connectivity via cellular, LoRaWAN, and satellite
Oil & Gas — Impact
48%
Reduction in HSE Incidents
72hr
Average Leak Detection Lead Time
$800K
Avg. Compliance Cost Savings
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Food & Beverage
Processing, Packaging & Cold Chain
Food and beverage manufacturers face intense regulatory scrutiny, tight margins, and zero tolerance for product safety failures. IIoT creates the traceability backbone required by modern food safety frameworks.
Core Challenge
Ensuring FDA/FSMA compliance, complete product traceability, and cold chain integrity requires real-time sensor data and automated record-keeping that paper-based systems cannot reliably provide.
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Complete lot-level product traceability systems
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Cold chain temperature and humidity monitoring
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Clean-in-place (CIP) automation and validation
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FSMA 204 / HACCP compliance automation
Food & Beverage — Impact
100%
Audit Readiness
22%
Waste Reduction
4×
Faster Recall Response
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Water & Wastewater
Municipal Water Systems & Treatment
Water utilities operate critical public infrastructure with small engineering teams, aging SCADA systems, and growing cybersecurity obligations.
Core Challenge
Many water utilities still operate on 20-year-old SCADA platforms with analog instrumentation, manual meter reading, and limited cybersecurity — creating operational and regulatory risk.
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SCADA modernization with cybersecurity hardening
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Remote pump station monitoring and control
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Real-time water quality monitoring
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AMI / smart meter integration and leak detection
Water & Wastewater — Impact
35%
Energy Cost Reduction
28%
Water Loss Reduction
80%
Reporting Time Savings
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Logistics & Warehousing
Distribution Centers & Supply Chain
Modern distribution operations demand sub-second inventory accuracy, optimized material flow, and automated exception management.
Core Challenge
Labor shortages, order accuracy expectations, and compressed delivery windows are forcing distribution centers to automate — requiring tight integration between automated equipment and business systems.
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RFID / barcode / computer vision inventory tracking
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AGV / conveyor monitoring and traffic management
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WMS / ERP real-time integration
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Dock door and yard management automation
Logistics — Impact
99.8%
Inventory Accuracy
40%
Throughput Increase
65%
Reduction in Mis-picks
Don't see your industry? Let's talk.
We've delivered IIoT solutions across many additional sectors.
Home / Solutions & Case Studies
Real Projects, Measurable Results
Every engagement is measured against a clear baseline. Here are case studies that demonstrate what IIoT done right looks like in practice.
Manufacturing
Central Valley Food Processor: Smart OEE & Predictive Maintenance
Client: Mid-size food processing facility, Fresno County, CA | Timeline: 7 months
A regional food processor with 12 production lines was experiencing chronic unplanned downtime averaging 6 hours per week. Manual OEE tracking on paper spreadsheets meant managers were always reacting, never anticipating.
The Challenge
Zero real-time visibility into machine health. Maintenance was purely reactive — leading to costly emergency repairs and lost production.
▸340 vibration, temperature, and current sensors across all 12 lines
▸4 edge computing nodes for local signal processing
▸Custom Grafana OEE dashboards with shift-by-shift tracking
▸ML predictive maintenance models trained on 18 months of data
▸CMMS integration for automated work order generation
Project Outcomes
34%
Reduction in unplanned downtime
$1.2M
Annual savings in maintenance & lost production
18%
OEE improvement across all lines
8mo
Full ROI payback period
MQTTInfluxDBGrafanaTensorFlowAWS IoTOPC-UA
Energy & Utilities
Agricultural Irrigation District: Remote SCADA Modernization Across 80 Miles
Client: Central California Irrigation District | Timeline: 11 months
80+ pump stations spread across 80 miles of canals. Their 1990s-era SCADA system was failing regularly, and every anomaly required a technician to drive out and diagnose — often spending 4+ hours per incident.
The Challenge
No cellular coverage at many stations, legacy PLCs with proprietary protocols, limited IT staff, zero cybersecurity.
▸Ruggedized IIoT gateways at all 80 stations with 4G/LTE + LoRaWAN
▸OPC-UA wrappers for legacy Modbus PLCs — no hardware replacement
▸Cloud SCADA on AWS IoT with offline edge buffering
Client: Multi-facility dairy cooperative, Tulare County, CA | Timeline: 5 months
A dairy cooperative processing 2 million pounds of milk per day faced a hard FDA FSMA 204 compliance deadline. Their paper-based lot tracking system would not meet the new requirements.
The Challenge
Three facilities, different ERP configurations, under 6 months — without disrupting a 24/7 operation.
▸Barcode + RFID scanning at every critical control point across 3 facilities
▸Middleware API integration with 2 different ERP systems
▸240 temperature sensors throughout cold storage and transit
▸Automated FDA-ready traceability reports and mock recall drill system
Project Outcomes
100%
FSMA 204 compliance — passed first audit
4×
Faster recall response (2hrs vs 8hrs)
22%
Reduction in product waste
0
Production hours lost during deployment
RFIDAzure IoTSAP IntegrationMQTTPower BI
Water & Wastewater
Municipal Water Authority: SCADA Hardening & Smart Leak Detection
Client: Community Water System, Kings County, CA | Timeline: 9 months
A municipal water authority serving 40,000 connections was operating a 20-year-old SCADA system with known cybersecurity vulnerabilities and an 18% non-revenue water loss rate.
The Challenge
EPA cybersecurity assessment flagged critical vulnerabilities. State Water Board required reduced non-revenue water losses within 24 months or face financial penalties.
▸Full SCADA network redesign with OT/IT air gap
▸180 acoustic leak detection sensors across the distribution system
▸1,200 aging meters replaced with AMI smart meters
Client: Independent E&P Operator, Kern County, CA | Timeline: 6 months
120 mature wellheads across Kern County needed to comply with new CARB emissions monitoring requirements while reducing the cost of manual well checks — their largest operational expense.
The Challenge
Remote terrain, no power, no connectivity, legacy pneumatic controllers. New CARB regulations required continuous emissions monitoring with audit-grade data logging.
▸Solar-powered edge controllers at all 120 wellheads
▸Satellite and private LTE data backhaul
▸Continuous methane / VOC sensors with automated CARB reporting
Project Outcomes
70%
Reduction in well check visits
100%
CARB compliance on first review
8%
Production uplift from optimization
$1.1M
Annual opex savings
Solar Edge IPCSatellite LTEAWS GreengrassModbus RTUCARB API
Client Testimonials
What Our Clients Say
"
Rust Mote didn't just deploy sensors — they fundamentally changed how we manage our operation. We went from fighting fires to preventing them. The ROI was faster than we projected.
DM
Dan M.
VP Operations, Food Processing Co.
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We were skeptical that any vendor could modernize our 30-year-old pump stations without replacing all our equipment. Rust Mote proved us wrong — and came in under budget.
JT
Janet T.
General Manager, Irrigation District
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The FSMA compliance deadline felt impossible. Rust Mote had us fully compliant two weeks early, across three facilities. Their team was professional, fast, and understood our business.
RC
Rosa C.
Quality Director, Dairy Cooperative
ROI Estimator
Estimate Your IIoT ROI
Enter your operational parameters and get a rough estimate of potential savings from an IIoT implementation.
📊 Estimated Annual Impact
Downtime Cost Reduction (34%)$340,000
Maintenance Savings (25%)$62,500
Energy Optimization (10%)$25,000
Quality / Waste Reduction$30,000
Total Estimated Annual Savings$457,500
Estimated ROI Payback~12 months
Estimates based on average outcomes across our client portfolio. Actual results vary by facility, industry, and scope.
Ready to start your own success story?
Schedule a free 30-minute consultation with one of our IIoT engineers.
Home / About
Industrial Expertise, California Roots
Built by engineers who spent careers on the plant floor — and saw firsthand what's possible when industrial systems get connected the right way.
Our Mission
Making Industrial Operations Smarter, Safer & More Efficient
We founded Rust Mote Inc. with one conviction: that the gap between industrial operations and modern digital technology doesn't have to be as wide as it is. Too many factories, utilities, and processors are leaving enormous value on the table.
Our mission is to close that gap — not with off-the-shelf software that doesn't fit, but with thoughtfully engineered solutions that meet industrial operations exactly where they are.
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Outcome-Driven
We measure success in ROI, uptime, and efficiency gains — not lines of code. Every engagement is oriented around measurable business outcomes.
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Engineering Rigor
Industrial environments don't tolerate flimsy solutions. We bring the same discipline to software architecture that our clients apply to their physical infrastructure.
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Long-Term Partnership
We don't deploy and disappear. Our relationships span years — because IIoT systems require ongoing stewardship to deliver lasting value.
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Security by Design
Cybersecurity is not an add-on — it is an architectural principle embedded in every solution we design.
Our Team
Meet the Engineers
MK
Marcus Kowalski
Founder & Chief Engineer
20+ years in industrial automation at Chevron and Pacific Gas & Electric before founding Rust Mote. Certified in IEC 62443 and ISA-99.
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Sarah Lin
Director of Data Science
PhD in Applied Mathematics from UC Davis. Specializes in time-series anomaly detection and predictive maintenance models.
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Raúl Gutiérrez
Head of Systems Integration
15 years of SCADA and DCS integration across oil & gas and food processing in the Central Valley. Expert in OPC-UA and Modbus.
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Anita Torres
OT Cybersecurity Lead
Former NSA cybersecurity analyst, now focused on protecting industrial control systems. IEC 62443 practitioner certified.
JM
James Morrison
Cloud Architecture Lead
AWS Certified Solutions Architect and Azure IoT specialist. Designs scalable, secure cloud infrastructure for our client deployments.
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Priya Varma
Client Success Manager
Former operations manager at a Valley food processor — she ensures every engagement delivers on its promised outcomes.
Our Story
Built Over a Decade in the Field
2009
Founded in Tipton, California
Marcus Kowalski incorporates Rust Mote Inc. after leaving Pacific Gas & Electric, seeing an underserved market for industrial IoT consulting in the Central Valley.
2012
First Major SCADA Integration
36-pump-station SCADA modernization for a Central Valley irrigation district — our first large-scale project and the template for dozens that followed.
2016
Expanded into Data Analytics & AI
Hired our first data science team. First predictive maintenance solution reduced unplanned downtime by 31% for a Fresno food processing client.
2019
OT Cybersecurity Practice Launched
Launched dedicated OT/IT security consulting aligned with IEC 62443 standards, responding to growing client demand and a more threatening landscape.
2022
200th Project Milestone
Celebrated our 200th completed engagement across manufacturing, energy, water, agriculture, and logistics in the Western United States.
2025
Edge AI Platform Deployed
Launched next-generation edge AI platform — bringing sub-10ms inference to the machine level for fully autonomous quality control.
By the Numbers
Rust Mote in Figures
200+
Projects Delivered
15+
Years of Experience
$40M+
Client Savings Generated
98%
Client Retention Rate
Ready to bring IIoT to your operations?
Our team of engineers is ready to assess your facility and build a custom solution.
Home / Contact
Let's Build Something Together
Tell us about your operation and we'll connect you with the right engineer. We respond to all inquiries within one business day.
We respond to all new project inquiries within 1 business day. For urgent operational needs from existing clients, contact your dedicated account manager or call our 24/7 NOC line.
Why Reach Out
What Happens When You Contact Us
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1. We Respond Fast
Every inquiry gets a personal reply from one of our engineers — not a sales rep — within one business day.
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2. Free Discovery Call
We schedule a 30-minute call to understand your operation, pain points, and goals — at no cost or obligation.
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3. Scoping Proposal
If there's a good fit, we develop a clear scope of work with transparent pricing — no surprises, no hidden fees.
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4. Move Fast
Most projects kick off within 2–3 weeks of contract signing. We don't leave you waiting months to start.