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CASE STUDY Early Vibration Detection Helps Beverage Facility Avoid Conveyor Downtime

Food-beverage-motor-sensor
INDUSTRY

Food and Beverage

EQUIPMENT TYPE
Motor
FAILURE MODE
Unbalance
IMPACT
$240K saved 
24 hours of downtime avoided 
7 days from initial alert to verified resolution
THE CHALLENGE

In beverage distribution facilities, uptime on packaging and baling conveyors is critical. At a major beverage facility, Waites' sensors identified a sudden increase in vibration on multiple components, particularly the baler fan motor. Left unresolved, this vibration could have led to an extended outage, disrupted packaging lines, delayed shipments, and incurred substantial operational losses.

PROBLEM IDENTIFIED

Waites' analysts detected significant spikes in velocity vibration (peak-to-peak) on the baler fan motor, gearbox, hydraulic pump, separator paddle, and heat exchanger fan. The simultaneous spike across multiple assets indicated a common root cause. Further inspection confirmed the cooling fan impeller on the heat exchanger had been damaged by metal wire from the baler, causing widespread elevated vibration levels.

food-beverage-motor-before

A sudden and significant increase in velocity vibration (0.7292 in/sec) along the gearbox input shaft Y-axis clearly indicates severe mechanical imbalance or internal damage.

food-beverage-motor-before-1

Sharp spikes in velocity vibration (0.3052 in/sec) along the X-axis further confirmed gearbox deterioration, highlighting the urgent need for immediate maintenance intervention.

food-beverage-motor-after

Following the replacement of the damaged fan impeller, vibration velocity quickly returned to normal operating levels, validating the effectiveness of the maintenance intervention.

QUICK RESOLUTION

Acting promptly on Waites’ early alerts, the maintenance team identified damage to the heat exchanger fan impeller, caused by baler wire interference. The damaged impeller was replaced, and associated equipment inspected. Subsequent vibration readings stabilized, confirming the successful resolution. Waites analysts remotely validated the effectiveness of the intervention.

$ 240,000
COST SAVINGS
24 Hours
DOWNTIME AVOIDED
7 Days
ALERT TO RESOLUTION

RAPID RESULTS

Thanks to predictive vibration analysis and immediate corrective actions guided by Waites, the beverage facility proactively avoided significant downtime. The quick resolution ensured continuous conveyor and baler operation, protected production schedules, and prevented substantial operational and financial disruptions.

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