How MV-X & NESTi4.0 improved maintenance for a Food & Beverage manufacturer

Customer : Major Food and Beverages producer

Region : Southeast Asia

Executive summary

A leading Southeast Asian beverage manufacturer was caught in a cycle of unexpected conveyor breakdowns, hindering production and inflating maintenance costs. Understanding the urgency, Acoem brought in the MV-X Realtime Online Vibration Monitoring System, seamlessly integrating with their setup. Data was fed into the NESTi4.0 predictive maintenance software platform, offering a bird’s-eye view of equipment health. Through Acoem’s patented Accurex™ AI, early faults were swiftly diagnosed, allowing for timely intervention. This proactive shift resulted in a 30% reduction in downtime, lower costs, and a more efficient production process—ensuring the company could deliver on its promises.

The problem

In a busy food production facility, the conveyor belt system is the backbone of operations. It ensures ingredients and products move seamlessly from one station to the next, allowing for high-speed processing and minimal manual handling.

At this facility, everything seemed to be running smoothly—until the conveyor belt system started slipping. At first, it was just a minor inconvenience: the belt would occasionally slow down or hesitate. But over time, this slippage became more frequent, resulting in significant delays in material handling. The conveyor, essential for keeping the ingredients flowing smoothly through the production line, was struggling to maintain its momentum.

Behind these delays lay several issues. Worn-out pulleys and insufficient tension were causing the belt to falter, and food residue began accumulating around the drive pulleys. Not only did this increase the risk of contamination, but it also led to operational bottlenecks. As food production halted intermittently, workers grew frustrated, and the team faced mounting pressure to meet customer demands while maintaining quality standards.

Recognising the urgency, Acoem’s team stepped in. During a thorough site visit, they used a blend of visual inspections, vibration analysis, and performance monitoring tools to understand the root causes. Here’s what they uncovered:

Belt slippage: The worn-out pulleys and lack of proper tension were the primary culprits, causing delays in material handling and affecting the smooth flow of production.
Irregular vibrations: Misaligned rollers and deteriorating bearings contributed to vibrations that threw off the system’s balance, further exacerbating the slippage issue.
Motor overloads: The increased mechanical resistance placed undue strain on the motor, raising the risk of failure and even longer production downtimes.

These persistent issues led to significant delays, rising maintenance costs, and unpredictable downtime, which ultimately took a toll on both production efficiency and team morale. The facility’s ability to meet customer expectations was being jeopardised, and the pressure to fix the problem was mounting.

The solution

Acoem’s solution went beyond the technical deployment of the MV-X Realtime Online Vibration Monitoring System; it became a true partnership. Acoem worked closely with the manufacturer, becoming a reliability partner by understanding their specific needs and challenges. By integrating the MV-X system with NEST software, Acoem empowered the team with real-time insights, helping them transition to predictive maintenance.

This shift didn’t just optimise operations—it gave the team confidence to act before issues arose. Through proactive alerts and easy access to data, the result was smoother operations, fewer disruptions, and a lasting, trusted partnership.

Deployment: The MV-X sensors were installed at critical points along the conveyor systems, continuously monitoring vibrations, alignment, and motor performance.
Real-time dData: The NESTi4.0 platform provided detailed insights into equipment condition, detecting early signs of wear such as abnormal vibrations.
Predictive maintenance: With data collected from MV-X, the company transitioned to a predictive maintenance approach, addressing issues before they led to costly repairs or operational stoppages. Proactive alerts were generated, allowing the maintenance team to act promptly

Key Insights:

Personalised approach: Acoem’s close collaboration ensured the solution met the manufacturer’s needs.
Strategic monitoring: Key sensors provided real-time insights on vital components.
Proactive maintenance: Early detection of potential issues, minimising unplanned downtime.
Outcome: Enhanced reliability, reduced downtime, and stronger operational efficiency.

The Results

The results of implementing the MV-X system went beyond just numbers—it transformed the way the team approached their operations.
The 30% reduction in downtime meant fewer interruptions, and machinery that once felt unpredictable became reliable.
The team found greater peace of mind, with fewer unexpected breakdowns and associated costs.
The equipment’s extended lifespan empowered them to focus on long-term improvements, leading to streamlined operations and on-time deliveries that met customer expectations.

Conclusion

Through careful analysis and the adoption of Acoem’s MV-X system, the beverage manufacturer transitioned from reactive to predictive maintenance. This approach didn’t just solve immediate equipment issues—it created an environment of possibility for long-term operational success. With real-time vibration monitoring, the manufacturer minimised downtime, reduced costs, and optimised production efficiency. This transformation empowered the team to build a more reliable and sustainable future, enabling them to confidently move forward.

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Acoem MV-x: Real-time monitoring for conveyor belt health

Acoem’s system provides continuous, real-time monitoring of conveyor belt components, detecting early signs of wear, misalignment, and vibration irregularities. By enabling predictive maintenance, it reduces downtime, extends equipment lifespan, and ensures smoother operations. This proactive approach helps food factories minimise costly disruptions, maintain hygiene standards, and keep production running efficiently.

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Acoem’s NESTI 4.0 integrates sensor data, machine learning, and cloud analytics to predict and prevent conveyor belt failures. It provides actionable insights into system performance, helping reliability engineers make data-driven decisions for proactive maintenance. This boosts operational efficiency, reduces energy consumption, and enhances overall productivity, ensuring a reliable and cost-effective conveyor system for food production facilities.