A food manufacturing facility leveraged MTI Wireless’s free two-week condition-based monitoring demo to evaluate risk on a 24/7 production line. With limited scheduled downtime occurring only once per month, early detection of mechanical issues was critical to maintaining output.
During the demo period, monitoring uncovered a developing mechanical condition on a critical oxidizer fan motor — preventing what could have been a costly and disruptive failure.
- Four dual-axis wireless sensors
- Velocity, acceleration, and temperature monitoring
- 10-minute transmission intervals
- Secure cloud-based dashboard with ISO alarm thresholds
- Monitor two oxidizer fan motors
- Identify early-stage mechanical degradation
- Reduce risk between scheduled maintenance windows
- Validate ROI of wireless monitoring
Trending Evidence & Corrective Action
Within several days, acceleration trends on one motor exceeded alarm thresholds. Lubrication was recommended, resulting in a temporary reduction. However, acceleration levels soon began increasing again — indicating a deeper mechanical issue.
Based on the trending data, MTI Wireless alerted the facility to a high risk of failure. The motor was proactively replaced before catastrophic breakdown occurred.
- Prevented catastrophic motor failure
- Avoided approximately $20,000 in product loss
- Reduced risk of unplanned downtime on a 24/7 line
- Validated ROI within a two-week demo period
- Provided data-driven justification for full system deployment
Conclusion
The free demo not only identified a developing failure but also provided clear, actionable evidence that empowered the facility to make a confident maintenance decision.
Impressed by the results, the client moved forward with a custom wireless monitoring system across the entire production line — increasing operational reliability and long-term cost savings.
