Plastic Extrusion Facility Saves $272K Annually With Perceptiv™ Diagnostic Services

Condition-Based Monitoring Reduces Downtime

Description of Problem

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 team was concerned an existing condition wouldn't be caught in time and productivity would be significantly impacted.

Description of Solution

The Perceptiv™ intelligence team recommended a monitoring and service package based on the customer's needs. To monitor current and vibration, S3100 sensors were installed on the extruder motor. Data was then examined to establish trends and set alarm levels. 

When abnormal vibration was detected, lubrication was recommended. This continued until additional lubrication no longer reduced the vibration levels, signaling a degrading motor condition. At that time, a motor rebuild was planned, which prevented additional motor damage and expensive unplanned downtime. This success has led to an expansion of the monitoring program with additional sensors being installed on other extruder motors. 

Benefits Seen By The Manufacturer Included

  • Problems were detected early so motors could be rebuilt for $12K vs. replaced for $80K.
  • Facility saves $272K annually (80K x 4 failures = $320K vs. $12K x 4 rebuilds = 48K), not including cost of the monitoring solution.
  • Quarterly, easy to read reports generated by an analysis expert with specific calls to action to avoid unplanned downtime
  • Time-trend analysis, condition-based alerts, and user-friendly, secure dashboard
  • Wireless vibration, IR thermography, temperature and electrical current sensors provide higher-resolution data and early indicators of equipment degradation

Related Resources

Wireless Technologies - A Practical Use Guide
A Practical Guide to Condition Monitoring
S3100 Product Sheet
Candy Manufacturer Saves $200K

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Solution Summary

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Perceptiv Intelligence

The demand for reliable assets has never been greater, yet finding the resources and knowledge has never been harder

Everyday there are challenges in labor resources, supply chain, meeting production goals and unplanned downtime. The Perceptiv intelligence team applies decades of industry and application knowledge to diagnose and design outcomes based on your needs. The team uses advanced technologies to detect issues before they become your problem to help increase profitability, efficiency, and overall plant health.

Diagnostic Services >

Technical tools are applied on-site for root cause analysis to assess equipment health. Receive easy to read reports on equipment performance along with prescriptive consultation to optimize your electromechanical powertrains.

Prescriptive Monitoring >

Manage assets with alerts, automatic trend detection and advanced condition monitoring tools. The Perceptiv condition monitoring services team can help with design and installation as well as regular reporting with prescriptive actions. Tie this system into your automation system or easily access information via the Perceptiv dashboard.

Maintenance, Repair, and Operations (MRO) Management >

Simplify MRO management for maintenance and procurement teams with the Tag-It Program. Reduce maintenance time, streamline procurement, and achieve inventory objectives by decreasing your MRO lifecycle up to 30%.

Perceptiv™ Solutions >

Our diagnostic services team has developed a series of solutions for the various industries we serve. Browse our documented solutions to get a baseline for how you can achieve optimal performance.


Regal Rexnord manufactures components that span the complete powertrain, and we have decades of application and industry knowledge. It’s truly an extension of who we are to monitor applications, provide insights, and recommend appropriate actions before issues interrupt production.

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