Case Studies

Coffee Production Company Success Story

Revolutionizing Europe's Leading Coffee Production: Enhancing Production Efficiency with ADI OtoSense Smart Motor Sensor

A global coffee producer’s drive to explore and adopt predictive maintenance solutions opened the doors for ADI’s OtoSense Smart Motor Sensor (SMS) solution. Equipment uptime improvement and growing operating margins were really important to the corporate management. This collaborative journey began in 2020 and has grown over the years with better understanding and implementation of predictive maintenance of rotating equipment through OtoSense technology.

The Challenges

Critical motors do not have redundancy leading to unplanned downtimes

Replacing rotating equipment or obtaining spare parts requires a long lead time, and the equipment itself is very expensive, leading to significant cost impacts in case of failure.

The Solution

Prevention of unexpected downtime, saving significant costs.

Optimization of “Cost of Ownership” for the critical assets.

Image of industrial coffee roaster

Implementation

In key coffee production plants across Europe, 80+ SMS units were deployed. The installation, commissioning, and learning process has been ongoing for two years. ADI OtoSense SMS was deployed in one of the top three factories in terms of annual coffee production, which includes a soluble area for green coffee covering roasting, extraction, evaporation, drying, filling and packaging processes.

 

A significant detection of a bearing fault on a critical motor underscored the importance of predictive intelligence systems. The SMS units on the critical ventilation system, driving primary air to dry coffee, identified the fault early. This early detection allowed the maintenance team to act promptly, avoiding costly motor replacement (€30,000) and production downtime (€20,000–30,000 per hour), resulting in substantial cost savings.

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ADI OtoSense Smart Motor Sensor Reduced Overall Costs

Reduce Downtime

Reduces unforeseen downtimes and avoids catastrophic failures

Reduce Overhauls

Extends period between overhauls

Optimize Maintenance

Reduces route-based activities & optimizes maintenance resource allocation

Efficiently Manage Resources

Manages spare parts and stock more efficiently

Extend Lifespan

Increases lifetime of your equipment

Optimize Efficiency

Optimizes motor efficiency

Improve Efficiency

Improves OEE (Overall Equipment Efficiency)

Benefit of ADI OtoSense Smart Motor Sensor

Advanced Diagnostics for Prioritized Action Items

Identifies electrical and mechanical performance degradation

Supports maintenance prioritization via assessment of severity levels

Provides repair insights and recommendations

Cutting-Edge Sensing Technologies for High Quality

Multi-axis, wide bandwidth vibration sensors monitor mechanical health

Magnetic field sensors monitor electrical health

Temperature sensors monitor ambient and motor skin temperature

Machine Learning Creates Motor Models During Operation

Combines and interprets high quality, sensing data for higher reliability diagnostics

Creates automated, brand agnostic motor models

Customized model for individual motor & the processes in which it is used

Photo of a coffee production company engineer

Maintenance Engineer

A Major Food/Beverage Manufacturer

"We were thrilled by SMS's ability to promptly identify the issue in the ventilation system. Given the substantial size and high replacement costs of the motors in our production line, along with lengthy lead times, maintaining them properly is essential. SMS has proven to be an ideal solution for this need."

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