Smart maintenance
for the beverage industry

A look at the shelves in the supermarkets reflects the situation in the beverage industry: new beverages come onto the market every week. Cut-throat competition prevails, the margins are rather small. In order to survive in this environment, companies in the beverage industry need every cent they can save. At the same time, more and more new products also mean longer set-up times and maintenance. Unplanned failures and standstills in production are then symbolically the camel's last straw. One possible solution is condition-based monitoring (CBM) with intelligent frequency frequency converters. It enables predictive maintenance. Such smart maintenance is already popular with global players. But it can also be worthwhile for smaller companies in the beverage industry.

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"How much does an hour of downtime in your production cost?"

In any case "too much", according to René Grywnow from Danfoss Drives. In the video, he shares tips for more efficiency in beverage production and uses the example of the bottling plant in the Doemens Academy's teaching and experimental brewery to explain how you can use smart drive technology in your bottling hall to save costs. Because what many do not yet know: In addition to higher energy efficiency through frequency-controlled processes, unplanned stops and unexpected maintenance requirements can also be prevented with intelligent frequency frequency converters. Behind this is a new technology, the so-called condition-based monitoring (CBM). frequency converter. The effort quickly pays off, because even an unplanned downtime of just one hour can quickly result in a loss of several thousand euros.

What is condition-based monitoring with frequency frequency converters?

In the beverage industry only a few drive systems are monitored with high-end condition monitoring software - because it is often too expensive. When such a system is used, it is mostly in critical areas. This can be changed and the advantages are manifold. And that's exactly why Danfoss Drives has the so-called Condition-based Monitoring (CBM). intelligent frequency converter frequency converter with integrated CBM functions quickly and reliably detect many errors in drive systems by monitoring the motor. Now there is one question above all: How exactly does condition-based monitoring with frequency frequency converters work? 

The principle behind CBM is quickly explained: Intelligent frequency converter collect (engine) data with the help of internal and up to four external sensors, store them and evaluate them with Edge Intelligence. The results are then available in the cloud or in a local control system. Based on this data analysis, operators are now planning predictive, condition-based maintenance that increases the performance, efficiency and uptime of plants, extends the service life of plant components and at the same time reduces complexity. How frequency frequency converters learn exactly is explained by the DanfossEngineers Jörg Dannehl and Holger Schmidt in Torque - The podcast driving you. The episode "How does an inverter learn?" is available in German.

Smart maintenance for high availability in the beverage industry

Now ask yourself what the use of CBM with frequency converter in the beverage industry? An example from the bottling cellar illustrates the advantages: the cleaning takes place there under high pressure. Disinfectant foams are also used. In the worst case, this can lead to water penetrating the motors during the cleaning process. This is exactly what CBM users can easily keep an eye on by monitoring the motor windings. If water does get into an engine during cleaning, you have an early indicator that shows an impending critical failure in good time. This gives you the time to check whether you have suitable spare parts in stock. So you will no longer be surprised by unplanned stops.

That's what the CBM users from the beverage industry say

In the CBM user talk in Torque - The Propulsion Podcast, hear how Molson Coors, a multinational brewery group that owns many prominent beer and beverage brands, uses CBM in their production facilities. Because for some time now, Jakov Perisic from Molson Coors and his team have been using condition-based monitoring frequency converter. Their goal is not only to make repairs more efficient, but also to run the systems longer overall. In episode 11 "Condition-based Monitoring: Using data, increasing system performance", Jakov explains how they manage to do this and what challenges they encounter in the process. Read the podcast interview right here.

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Why is speed control of pumps worthwhile?

As in all process industries, pumps also play an important role in the beverage industry. If these pumps are frequency-controlled, production efficiency increases and users save a lot of money by reducing energy and costs. It is therefore worthwhile, on the one hand, to consider the speed control of the pumps from the outset when planning new systems. On the other hand, existing systems can also be easily retrofitted in most cases. 

In addition to increasing efficiency and reducing costs, the use of intelligent frequency frequency converters in pump control enables completely new maintenance strategies with condition-based monitoring. Christian Prakesch from Danfoss Drives explains what that means in detail in the video. 

New maintenance strategies with variable speed pumps

If intelligent frequency frequency converters drive pumps in the beverage industry, completely new paths can also be taken in maintenance. Condition monitoring of pumps with CBM-enabled frequency converters enables users to identify risks at an early stage and avoid production stops.

It works as follows: The frequency converter creates an image of the system using internal signals that the converter knows from the motor, such as current, power, speed or torque. He sends this picture to the plant operator. At the request of the operator, this overview can then be further refined. If, for example, additional external sensors are connected, a wide variety of limit values ​​can be checked and monitored. The result is a very precise determination of the necessary maintenance intervals by the Edge Intelligence in the converter.

In addition to the great benefits that the speed control of pumps brings for smart maintenance in the beverage industry, the well-known advantages relating to energy and cost efficiency naturally remain. The rule of thumb is that even with a speed reduction of 20 percent, around 50 percent of the energy is saved. 

Would you like to know more? Read how Danfoss AC drives can help you save energy and Increase sustainability in your production and what savings potential the internationally renowned Doemen's Academy in their new teaching and experimental brewery with efficient and flexible drive technology from Danfoss. More tips and in-depth knowledge about the smooth use of pump applications in beverage production can be found in this Tech Insight [link if created].

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