Predictive maintenance in the food industry

The ADI OtoSense intelligent motor sensor is designed to monitor and diagnose the performance of industrial motors used in the food industry. With it, it is possible to collect precise real-time data on the operation of motors, including parameters such as temperature, vibration and energy consumption.

The data collected is processed and analyzed using Artificial Intelligence (AI), allowing for the early detection of possible faults and the identification of abnormal performance trends. This analysis provides a clear view of the state of the engine, carrying out optimized diagnostics for each individual unit.

This way, if any anomalies are identified that could indicate a possible engine problem, warnings are issued on the dashboard and recommendations are provided to solve the problem. The plant information dashboard can be accessed via the solution's application or via a computer browser.

By adopting this solution, companies in the food industry can take preventive measures to avoid unscheduled downtime and minimize the risk of financial and raw material losses. Predictive maintenance can thus help to increase operational efficiency, reduce maintenance costs and extend the useful life of equipment.

In addition, one of the great differentiators of ADI's OtoSense intelligent motor sensor is its ability to detect magnetic flux, which most sensors available on the market today do not. This is important because magnetic field deviations are the source of temperature and vibration anomalies, meaning that this sensor allows predictive maintenance to act at an earlier stage than temperature and vibration changes.

Nissei, the famous Japanese ice cream manufacturer, was the first company to introduce soft serve ice cream in Japan. The company develops the ingredients for ice cream, including the mix, shells, toppings and waffles, as well as manufacturing the special freezers needed to store the product.

To keep up with the new challenges of Industry 4.0, the traditional machine ice cream manufacturer is undergoing a digital transformation, and testing the smart motor sensor is an important part of this effort.

According to Nissei's production manager, Yoshiro Murakami, emulsification is a critical process in the production of an ice cream mix. If a problem occurs with the homogenizer, emulsification becomes impossible, and product quality cannot be properly maintained. "This has a significant negative impact on production costs and labor, and raw materials are wasted," said Yoshiro.

To ensure that production machines are working to the standards required by the food industry, Nissei uses ADI's OtoSense intelligent motor sensor. With it, predictive maintenance is carried out on the homogenizers in the ice cream factory.

This way, Nissei's maintenance and equipment renewal planning can also be implemented and negotiated from a reliable database. "In the future, we plan to optimize the frequency of maintenance, which will further reduce costs. We are currently embarking on a company-wide digital transformation journey, which includes a project called Smart Factory NISSEI," said Yoshiro.

Macnica ATD Europe and ADI OtoSense are committed to providing cutting-edge technological solutions that drive the food industry towards operational excellence, such as the smart motor sensor. With it, companies can take their maintenance processes to the next level, ensuring a continuous flow of production and minimizing the negative impacts of unplanned downtime through the use of AI.

Are you interested? Do you want to implement this solution and start the digital transformation of your factory, making it smarter, safer and more efficient? Click here, contact us and find out more about the ADI OtoSense intelligent motor sensor.