Traditional equipment maintenance can be predetermined – run it every 1000 hours or every 500,000 litres – or corrective – fix it when it breaks. But thanks to digitalised services, Tetra Pak is now able to offer Condition Monitoring: a new approach that can predict failures before they occur, allowing customers to plan maintenance and save hours or even days of downtime.
Rather than risk either failure or too-frequent replacement of components, Condition Monitoring uses sensors to monitor their operating environment or internal state. Captured data is sent to our Performance Management Centre, where algorithms analyse the machine’s behaviour and predict when failure is likely to occur – and so when parts need to be replaced.
Condition Monitoring provides customers with an unprecedented opportunity to improve plant efficiency, by enabling replacements to be scheduled during routine maintenance stops, preventing unplanned stops, optimising maintenance intervals and improving productivity. The service can also be tailored to monitor vibrations, lubrication, power circuits or acoustics, as well as process flows, pressures and temperatures.
Customers are already experiencing the benefits. In one case, Condition Monitoring predicted a servo motor breakdown 100 days prior to failure, sparing the customer 48 hours of downtime. Another customer avoided 36 hours of downtime after Condition Monitoring detected worn bearings and a damaged coupling. The service also detected an incidence of incorrect belt tension for a customer in South America, which helped prevent accelerated wear and breakdown.
Overall, the new digital technology made available by Tetra Pak Services is helping to ensure that customers’ food manufacturing runs smoothly and delivers on time and in full. Systematic monitoring also benefits ongoing product and service development, since it enables our design, engineering and technical staff to modify maintenance recommendations, contributing to the development of even better equipment.