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CASE STUDY Detecting Slow-Speed Bearing Failure Prevents Equipment Fire in Roasting Room

Enhanced ultrasonic vibration monitoring caught a fault that low speed kept quiet — 23 minutes from alert to verified action item.
roaster-sensor

INDUSTRY
Food & Beverage

EQUIPMENT TYPE
Motor
FAILURE MODE
Structural Looseness
IMPACT
$734K saved 
72 hours of downtime avoided 
19 days from initial alert to verified resolution

THE CHALLENGE

Condition monitoring sensors flagged an increase in vibration velocity in a low-speed bean roaster that was verified by ISO certified vibration analysts as an early failure in the motor bearings and gearbox drive end.

During continuous monitoring of a global food and beverage manufacturer's bean roasting equipment, a developing mechanical defect was caught by Waites' AI-driven and analyst verified vibration analysis solution. The roaster's drum turned at a very low speed, so the anomaly didn't produce the loud noise or heavy vibration that usually gives away a problem on faster equipment.

PROBLEM IDENTIFIED

Monitoring the roasting room 24/7, the Waites analyst team caught a rise in velocity on the motor driving the drum and flagged it as a failing bearing for further inspection as a priority alert. The facility's maintenance team moved the action item forward, inspected the motor, and found wear and looseness in the coupling that connected the motor to the gearbox. Further inspection confirmed both the motor and the gearbox drive-end bearing were failing.

As soon as the issue was identified, Waites' machine learning team sent a verified action item with guidance to facility personnel in less than half an hour. After repair, the analyst confirmed levels had dropped back below baseline.

roaster-velocity-waterfall
Condition monitoring sensors flagged an increase in vibration velocity in a low speed  bean roaster that was verified by ISO-certified CAT II+ experts as an early failure on the motor bearings and gearbox drive end.
roaster-motor-velocity
Velocity levels climbed on the motor driving the roaster drum until analysts verified the fault and issued a priority action item. After repair, levels dropped back below baseline.

RISK REDUCTION

Left unaddressed, the bearing failure posed a critical operational safety hazard, putting the facility at risk of process contamination and multiple days of clean up. Catching this fault early spared a leading food & beverage corporation from a potential fire, protecting personnel, property, and production.

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Why Waites? Precision Monitoring. Our continuous condition monitoring solution and ultrasonic-range capabilities catch increases in vibration velocity in slow-rotating equipment.

$ 734,400
COST SAVINGS
72 Hours
DOWNTIME AVOIDED
23 Mins
ALERT TO ACTION ITEM

RAPID RESULTS

By flagging the velocity rise, verifying the fault in under half an hour, and handing maintenance a clear action item, Waites kept a slow-speed bearing failure from becoming a fire in the roasting room.

DOWNTIME ENDS HERE.

PROTECT YOUR CRITICAL ASSETS

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