Plasthill prevents costly downtime with Sensorfact’s vibration sensors

The start

Plasthill, like many other manufacturing companies, struggled with the challenges of reactive maintenance. “Before we worked with Sensorfact, we relied on reactive maintenance,” says Johan Kerzaan, Maintenance Engineer at Plasthill. “This often led to unexpected downtime, production interruptions, and high costs. We needed a way to predict and prevent problems, rather than fixing them afterward.” Plasthill sought a solution to optimize their maintenance process, increase the reliability of their machines, and reduce overall operational costs.

The solution

Sensorfact offered Plasthill a solution in the form of advanced vibration sensors and a software platform. This solution enables Plasthill to continuously monitor the condition of their machines, particularly on critical equipment such as extruders. The vibration sensors measure vibrations and other parameters, and the data is analyzed by Sensorfact’s team. By identifying deviations and trends in the data, Sensorfact can detect potential problems early, before they lead to machine failure.

The results

The implementation of the Sensorfact solution has led to significant benefits for Plasthill:

• Cost savings: Plasthill has saved a lot of potential costs through proactive maintenance, resulting in an ROI of 7.55. Recently, bearing damage due to fluting on the motor of an extruder was detected early and accurately diagnosed by Sensorfact. This allowed Plasthill to schedule maintenance accordingly before failure and prevented significant downtime which resulted in a substantial saving.
• Reduced downtime: Early detection of potential issues enables Plasthill to plan proactive maintenance and avoid unplanned downtime, increasing productivity.
• Optimized maintenance: Sensorfact’s data analysis provides insights into machine condition, enabling Plasthill to optimize their maintenance strategy for greater efficiency and extended machine lifespan.