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Digital plant solutions support flexible manufacturing

Many food and beverage companies are experiencing growing pains with digital platforms, but manufacturing is still about asset management processes, selecting the appropriate technology solution and letting the workforce grow with these tools.

Olam International identified low-voltage motors for better remote monitoring with its digital pilot project and is now monitoring vibration, bearing health and cooling efficiency, among others.
Olam International identified low-voltage motors for better remote monitoring with its digital pilot project and is now monitoring vibration, bearing health and cooling efficiency, among others.

Exception-based monitoring for operators is what many plant managers have identified as the crucial first steps in adding sensing to the factory floor and executing better efficiencies for production lines. (See “Smart manufacturing applications say hello to food processors.”) However, new digital plant solutions only work as well as the nondigital operational procedures and processes that are in place. 

“Once manufacturers have studied their processes and know the critical information, then the data has to be reliable and accurate every single day,” says Jim Wetzel, interim CEO of the Clean Energy Smart Manufacturing Innovation Institute. “In my time at General Mills, we were collecting over 700 billion data points a day, and probably 98 percent of those we never used every day.”

Wetzel spent 32 years at General Mills in many different management roles, including director of global reliability. He oversaw the implementation of General Mills’ manufacturing execution system (MES) in the 1990s.

Olam International Ltd., another sizeable multinational supplier of food and raw materials, recently implemented pilot projects to monitor a large number of conveyor motors at many of its plants via ABB’s Ability Smart Sensor, a stand-alone sensing platform. Originally introduced at the Hannover Fair in 2016, this sensing and monitoring platform targets low-voltage motors and attaches to the actual motor’s outer casing. 

The platform monitors vibration, bearing health, cooling efficiency, air-gap eccentricity, rotor winding health, skin temperature, energy consumption, loading, operating hours, number of starts and revolutions per minute speed.

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