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CASE STUDY Early Detection of Temperature and Vibration Issues Prevents Conveyor Downtime at Building Materials Facility

building-materials-conveyor-sensor
INDUSTRY

Building Materials Manufacturing

EQUIPMENT TYPE
Conveyors
FAILURE MODE
Temperature/Overheating
IMPACT
$318K saved 
60 hours of downtime avoided 
25 days from initial alert to verified resolution
THE CHALLENGE

The forming section conveyor in building material plants is crucial for maintaining a smooth and uninterrupted production flow. Waites' sensors identified unusual increases in temperature and irregular vibration levels on the conveyor’s drive roll bearing. Without swift intervention, the facility risked extended downtime, potentially halting production, delaying deliveries, and resulting in significant financial losses.

PROBLEM IDENTIFIED

Waites' analysts detected significant increases in temperature and irregular vibration patterns (peak-to-peak acceleration spikes and unstable velocities) on the conveyor's drive roll bearing. Initial inspections involved lubrication and checking surrounding components for debris buildup and proper clearances. However, detailed analysis and maintenance inspections ultimately confirmed that the bearing had internally failed, causing excessive heat and vibration.

building-materials-conveyor-before

Steady temperature rise on the drive roll bearing indicated internal bearing deterioration, prompting urgent maintenance action.

building-materials-conveyor-before-1

A sharp increase in peak-to-peak vibration (33.40 g) clearly indicated significant bearing deterioration, highlighting the urgent need for immediate maintenance intervention.

building-materials-conveyor-after

Post-maintenance data shows vibration levels returning to normal, validating successful corrective actions.

QUICK RESOLUTION

Responding swiftly, the maintenance team replaced the damaged bearing, which had internally failed. They also lubricated the bearing, thoroughly inspected clearances, cleaned the surrounding conveyor components, and repaired forming section oilers. Post-maintenance sensor data showed temperature and vibration levels returned to normal, confirming the effectiveness of the intervention.

$ 318,240
COST SAVINGS
60 Hours
DOWNTIME AVOIDED
25 Days
ALERT TO RESOLUTION

RAPID RESULTS

Thanks to the timely detection of both temperature and vibration anomalies, and recommendations from Waites, the facility replaced the internally damaged bearing quickly. This proactive response prevented substantial downtime, maintained continuous conveyor operations, and safeguarded critical production schedules.

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