Machine Condition Monitoring for the Food and Beverage Industry

Download the printer-friendly Condition Monitoring for the Food and Beverage Industry Application Note

The fast-paced, high-volume, and tightly regulated plant environment of the food and beverage industry means that downtime is not an option. As a result, developing an efficient maintenance program is critical for food and beverage plant operations. In large-scale manufacturing plants, maintenance costs incurred from reactive maintenance and unexpected downtime can range from 15% to 40% of total production costs. That is why predictive maintenance is quickly replacing reactive maintenance as an imperative cost-saving measure.

CTC is proud to offer a comprehensive portfolio of vibration analysis products engineered to meet the specific needs of food and beverage applications for both critical and non-critical machines, including:

Air handling units
Conveyors
Motors
Pumps
Compressors
Centrifuges
Mixers
And many more

Common faults of machinery used in food and beverage manufacturing include:

Unbalance
Misalignment between the sheaves
Looseness
Belt resonance defects / worn belts
Worn or damaged sheaves
Bearing defects
Rubbing
Motor electrical, including rotor bar faults

Workers in protective gear operating machinery on the floor of a chocolate manufacturing plant.

The first consideration is whether utilizing Process Monitoring or Dynamic Vibration Analysis is right for your condition monitoring program.

Process Monitoring
Process Monitoring requires 4-20 mA Loop Power Sensors that provide the overall vibration level of the machine so it can be trended and alarmed using the plant's DCS, PLC, or SCADA system. It also requires permanent mounting of loop power sensors that output a 4-20 mA signal proportional to velocity or acceleration. Process Monitoring will provide an overall understanding of machine health, but cannot provide the same level of detailed diagnostic data as Dynamic Vibration Analysis. It is a cost-effective way to get an understanding of machine health.

Dynamic Vibration Analysis
Dynamic Vibration Analysis allows for trended data and machine health diagnostics. However, Dynamic Vibration Sensors can be paired with CTC Signal Conditioners to create a hybrid approach for both Process Monitoring and Dynamic Analysis. A signal conditioner converts the signal from a dynamic sensor into a 4-20 mA output, so it can be trended and alarmed using the plant DCS, PLC, or SCADA system, and may also be used for more in-depth predictive maintenance. For highly critical machines, CTC recommends utilizing a dynamic accelerometer paired with a signal conditioner for real-time monitoring and in-depth analysis.

Loop Power Sensor Offerings for Process Monitoring
4-20 mA monitoring will provide a cost-effective online process monitoring solution for the food and beverage industry. Our standard LP200 and LP300 Series Sensors can be permanently mounted for a 4-20 mA output proportional to vibration in velocity or acceleration, respectively. CTC's Loop Power Sensors can also be paired with our PMX1000 Enclosures to display overall vibration levels with additional capabilities to alarm and shutdown.

Side and top exit CTC Loop Power sensors engraved with CTC Line logo, part number, serial number, data matrix, and CE logo.
LP202 Loop Power Sensor, 4-20 mA Output Proportional to Vibration in Velocity, Top Exit 2 Pin Connector
and
LP204 Loop Power Sensor, 4-20 mA Output Proportional to Vibration in Velocity, Side Exit 2 Pin Connector

Side and top exit CTC LP300 Series Loop Power sensors engraved with CTC Line logo, part number, serial number, data matrix, and CE logo.
LP302 Loop Power Sensor, 4-20 mA Output Proportional to Vibration in Acceleration, Top Exit 2 Pin
Connector and
LP304 Loop Power Sensor, 4-20 mA Output Proportional to Vibration in Acceleration, Side Exit 2 Pin Connector

A fiberglass PMX1000 enclosure with the door closed to show four digital displays on the front.
PMX1500 Vibration Relay & Display System for Single Output Loop Power Sensors, with Options to Include Switch Relay or Display Only, Fiberglass Enclosure, NEMA 4X (IP66) Rated, Input Options: 1 to 4 Single Output Loop Power Sensors

100 mV/g Accelerometers for Dynamic Vibration Monitoring
100 mV/g accelerometers are considered general-purpose accelerometers and typically meet the needs of food and beverage operations. In limited access areas, like near belt guards, side exit connector accelerometers are typically suggested. CTC's Dynamic Vibration IEPE Ultrasound Sensor also provides an excellent solution for general-purpose monitoring with the ability for high-frequency fault detection.

CTC AC102 and AC104 standard size top and side exit vibration sensors
AC102 General Purpose Accelerometer, Standard Size Top Exit 2 Pin Connector, 100 mV/g, ±10%
and
AC104 General Purpose Accelerometer, Standard Side Exit 2 Pin Connector, 100 mV/g, ±10%

AC292 and AC294 top and side exit compact size vibration sensors
AC292 Premium General Purpose Accelerometer, Compact Top Exit 2 Pin Connector, 100 mV/g, ±5%
and
AC294 Premium General Purpose Accelerometer, Compact Side Exit 2 Pin Connector, 100 mV/g, ±5%

CTC UEB332 and UEA332 mini top and side exit ultrasound sensors.
UEB332 Dynamic Vibration IEPE Ultrasound Sensor, Top Exit 2 Pin Mini-MIL Connector, 100 mV/g, ±10%
and
UEA332 Dynamic Vibration IEPE Ultrasound Sensor, Side Exit 2 Pin Mini-MIL Connector, 100 mV/g, ±10%

Cables and Connectors
Due to the caustic washdowns commonly used in food and beverage plants to maintain sterile conditions, CTC recommends using the world's most reliable cables and connectors including robust, chemically resistant connectors such as the A2N nylon connector or V Series Viton® boot connectors.

A black nylon A Series connector with stainless steel locking ring connected to a standard size side exit CTC accelerometer
A2N Standard Accelerometer Compatible Connector, 2 Socket MIL-Style, Nylon Molded, Permanent Mount, 250 °F (121 °C) Max Temp

A Series Connectors are a general-purpose offering that works in a variety of environments. A Series Connectors come with a stainless steel locking ring and a variety of material options, including polycarbonate, PPS, and nylon.

A black Viton boot style connector connected to a standard size, side exit CTC acclerometer.
V2N Standard Accelerometer Compatible Connector, 2 Socket MIL-Style, Seal-Tight Viton® Boot Connector with Nylon Insert, Permanent Mount, 250 °F (121 °C) Max Temp

V Series Viton® Boot Connectors are a premium offering for the best chemical resistance and an IP69 rating for moisture concerns.

Junction Boxes
Junction Boxes can be used for local measurements or the transmission of data to online vibration monitoring systems. Junction Boxes can also be used for cable reduction purposes or for switched outputs during manual route data collection of the vibration signals. Depending on the environment in which your box is mounted, CTC offers the majority of our enclosures in either fiberglass or stainless steel options.

A chart showing a comparison of the features of CTC Mini-Maxx, Maxx, SB, and JB Boxes.

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