Perceptiv team uses advanced techniques to identify recurring failures in critical mixing equipment

Customer Challenge

A major North American-based candy manufacturer was experiencing numerous problems with their critical mixing equipment since installation. They were experiencing shaft failure on a recurring basis, leading to damage. Downtime cost approximately 12 hours and $18,000 per hour, or $216,000 per breakdown. The equipment had already failed three times and cost them $648,000. The manufacturer reached out to several companies for help, but none could provide a lasting solution. Then, the company called in the Perceptiv, a Regal Rexnord brand, for assistance.

Regal Rexnord Solution

The Perceptiv team performed microscopic examinations of the shaft and a chemical analysis of the steel which revealed a fracture caused by torsional fatigue.

To determine the source of the fatigue, the team performed a motor current signature analysis, vibration analysis, and infrared thermography. The tests revealed several problems contributing to poor mixer performance--movement in the mounting base, torsional resonance, and inadequate process monitoring. High vibrations were preventing the mixer drivetrain from reaching the as-designed speed and throughput values. The Perceptiv team developed a plan to mitigate the issues, including changes to the shaft to eliminate stress points; re-orienting the arrangement of the mixing paddles; better equipment anchoring; and improved monitoring practices. After implementing the recommendations, the manufacturer soon reported that the mixer was performing better than it ever had.

Benefits Seen by the Plants Included

• Saved downtime cost of $216,000 per failure
• Received detailed analysis and recommendations that provided actionable solutions
• Eliminated equipment defects to prevent recurring breakdowns and improved condition monitoring solutions for early detection

The demand for reliable assets has never been greater, yet finding the resources and knowledge has never been harder

Everyday there are challenges in labor resources, supply chain, meeting production goals and unplanned downtime. The Perceptiv intelligence team applies decades of industry and application knowledge to diagnose and design outcomes based on your needs. The team uses advanced technologies to detect issues before they become your problem to help increase profitability, efficiency, and overall plant health.

Diagnostic Services >

Technical tools are applied on-site for root cause analysis to assess equipment health. Receive easy to read reports on equipment performance along with prescriptive consultation to optimize your electromechanical powertrains.

Prescriptive Monitoring >

Manage assets with alerts, automatic trend detection and advanced condition monitoring tools. The Perceptiv condition monitoring services team can help with design and installation as well as regular reporting with prescriptive actions. Tie this system into your automation system or easily access information via the Perceptiv dashboard.

Maintenance, Repair, and Operations (MRO) Management >

Simplify MRO management for maintenance and procurement teams with the Tag-It Program. Reduce maintenance time, streamline procurement, and achieve inventory objectives by decreasing your MRO lifecycle up to 30%.

Perceptiv™ Solutions >

Our diagnostic services team has developed a series of solutions for the various industries we serve. Browse our documented solutions to get a baseline for how you can achieve optimal performance.

Schedule a Time to Learn More About Perceptiv Solutions

Regal Rexnord manufactures components that span the complete powertrain, and we have decades of application and industry knowledge. It’s truly an extension of who we are to monitor applications, provide insights, and recommend appropriate actions before issues interrupt production.