Solution Stories with Perceptiv™ Intelligence

Growing Footprint of Reliability Systems

In the past, condition monitoring and predictive maintenance were only applied to critical rotating equipment in industries like oil and gas, steel mills, or high-end processing. Today, with lower cost technologies being applied to machines that were usually not measured with this higher end equipment, we are seeing reliability systems used across a much greater range of equipment and industries.

Coupling Recertification Saves Plants Time and Money

Unplanned downtime can be incredibly costly when you consider lost production and the stress of having to scramble for replacement parts and staff emergency labor (oftentimes at overtime rates).

IMI Quarry Prevents Downtime Due to Storms

Irving Materials, Inc. is a building materials supplier that operates in the Midwest and southern United States. IMI Aggregates, a division of the company, provides crushed stone, sand and gravel from their many Indiana locations. One of their sites has several dewatering basins on-premises designed to capture rain, ground or seepage water. These are located in remote areas of the quarry and help keep water away from the production pits.



Wireless Technologies – A Practical Use Guide

The market for wireless technologies has exceeded $1B annually and is expected to grow as global competition in manufacturing pushes facilities to ensure that their operation is performing at optimal levels and at the lowest total cost of ownership.  

Perceptiv Services Alerts Steel Mill to Torque Spikes

Steel mill gains $2M cost avoidance by utilizing Perceptiv intelligence to avoid catastrophic damage to equipment and unplanned downtime.

Improving Coupling Reliability

Kop-Flex has been recertifying couplings for over 15 years and services more than 150 couplings per year. The team does a full teardown and inspection of each component. They replace components as needed with new parts made to the original drawings and design standards. Recertification restores couplings to a like-new condition for about half the cost of a replacement.

Benefits of Proactive Maintenance

What if you could see the future and change it? Proactive maintenance is shown to cost up to 77% less than reactive maintenance. Find out Perceptiv(tm) intelligence can help you meet your cost-reduction goals

Advanced Technologies and Financial Benefits

A focus on monitoring critical asset health provides the basis to decrease life cycle costs of assets. The objective is to use reliability centered maintenance (RCM) methodologies to not only find the defects, but to eliminate as many defects as possible. A dynamic defect elimination program will analyze the failures and attempt to eliminate the defects. 

Perceptiv HVAC Diagnostics Solution

The Regal HVAC industry specialist and application engineering used Perceptiv to provide a two-step solution. First, an HVAC unit was selected as a test unit and the existing belt was analyzed. Application Engineering selected an “optimized” drive using notched v-belts. This allowed for a reduction in the number of belts required for the drive.

Preventive and Predictive Methods for Torsional Vibration

Torsional vibration describes the angular movement of a shaft(s) in a drivetrain, which is superimposed on the steady-state rotational movement of a rotating or reciprocating machine1 . More simply, torsional vibration refers to the angular or ‘twisting’ movement of the rotating shafts that connect the various pieces of equipment in a drivetrain. 

Vibration Detects Boiler Pump Issue

Wireless system alerts team and saves brewery from losing a day of operation equal to 5,600 cases and $100,000 in lost production.

Kiln ID Fan Torsional Vibration

  • Facility experienced (2) catastrophic failures of motor-driven ID fan, losses of $100k /day

  • Occurred after facility replaced fluid drive with VFD

  • Diagnostics performed to identify and correct harmful torsional vibrations

  • Strain gage telemetry system to measure transient torques

  • Bearing Vibration Rotational speed

Perceptiv™ Aluminum Mill Solution

A large North American mill was suffering coupling failure on one of their hot rolling reversing aluminum mills every 5 to 7 months due to premature wear on the coupling gear teeth. The wear on the gear teeth was caused by a coupling retaining ring that would crack. 

Perceptiv™ Solutions For the Aggregate Industry

Regal team members installed a state-of-the-art Perceptiv™ monitoring system on the shaker screen. The monitoring system detected changes in the operation, reliability and performance of the equipment. This information helped the quarry operations team schedule a shutdown to clear the blocked screen and address other problems.

Bottle Line Productivity Increased with Conveyor Guiderail Solution

Changing guiderail width to accommodate various container sizes is time consuming. Regal offered a unique solution with turnkey installation services to reduce time required to changeover conveyor guiderails. This enabled a production gain of $105,000 annually.

A new and virtual reality for maintenance

The widespread adoption of predictive maintenance (PdM) technologies is a testament to the early adopters who pioneered their use in industrial applications. These technologies transformed the way we think about maintenance by providing the ability to ascertain the health of an asset without interfering with its operation.

Basic Troubleshooting of Common Rotating Equipment

Technology has brought us many fantastic monitoring and troubleshooting tools such as vibration measurement, ultrasonic testing, power quality measurement, oil sampling, torque monitoring using strain gage technology, thermal imaging cameras, laser alignment equipment et. al. 

Implementing AR for Proactive Maintenance Achieves a $20K Monthly Savings

The roll forming machine is critical to the operation of the manufacturing facility, and accounts for a 25% loss of total production when it goes down unexpectedly. The roll forming machine is critical to the operation of the manufacturing facility, and accounts for a 25% loss of total production when it goes down unexpectedly. Read how the Perceptiv intelligence solution achieved a 155% ROI.

Proactive Asset Management with Wireless Condition Monitoring

According to a recent study, unplanned downtime costs industrial manufacturers an estimated $50 billion annually. Of this unplanned downtime, 42% is due to equipment failure. See how being proactive can save time and money.

Sifting Through the Noise: A Practical Guide to Condition Monitoring for Rotating Equipment

As the saying goes, “hope isn’t a strategy”, so while it may be tempting, it isn’t recommended to simply buy sensors off of the internet and hope for the best. This guide will walk through practical considerations to help you determine the right type, size and scope of monitoring technology and/or services for your application.


Lowering the Cost of Unplanned Downtime

With unplanned downtime costing industrial manufacturers an estimated $50 billion annually, companies are looking to implement preventive maintenance and automation technologies to monitor conditions of equipment. Find out more.

Setting Baseline References for Vibration Analysis

Vibration analysis is used to monitor the condition of rotating equipment and predict equipment issues based on data trends. The first step to successful vibration analysis is establishing relevant baseline references.


Candy Manufacturer Saves over $200,000 with Perceptiv™ Diagnostic Services

A major North American-based candy manufacturer was experiencing numerous problems with their critical mixing equipment including shaft failure on a recurring basis, leading to damage and resulting in downtime cost approximately 12 hours and $18,000 per hour, or $216,000 per breakdown.

The Newest Innovation in Smart Commercial Refrigeration

In the food and beverage retail industry, success hinges on the strength of your refrigeration equipment. An unexpected failure can result in case after case of food waste. A small repair can mean two or three service calls. And even a single broken refrigeration unit can mean thousands of dollars in lost sales.

Recycling Facility Saves $282K with Real Time Torque Data

At a large metal recycling facility, driveshaft coupling failures from transient torque overload events were causing unplanned shutdowns and lost production. Perceptiv™ intelligence connected services team prescribed the Expert S7000 Shredder Torque Monitor, a continuous torque monitoring system.

Plastic Extrusion Facility Saves $272K Annually

A large flower pot manufacturing facility was experiencing 3-4 unexpected motor failures per year, causing production disruptions on their plastic extruder drivetrains. Each failure costs $80K per drivetrain, totaling $320K in annual capital expenses, excluding hourly downtime. The Perceptiv™ intelligence team recommended a monitoring and service package based on the customer's needs.

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Commercial Systems|Industrial Systems