Acoustic emission technology minimises downtime

Established in 1886 Whitworth Bros Ltd supplies flour to some of the largest food manufacturers in the UK. The company operates from production sites located in Wellingborough, Northamptonshire and Peterborough in Cambridgeshire and supplies flour in Bulk loads as well as bag deliveries.

As one of the UK's largest independent flour millers Whitworth Bros Ltd prides itself on its ability to supply its customers with high-quality food-safe products that fulfil their customers' expectations. Whitworth Bros Ltd has recognised the importance of monitoring key elements of plant and equipment to ensure the company is always able to meet customer demands.

With a view to moving from a reactive to a proactive maintenance strategy, WBL took the decision in 2009 to invest in the MHC-Memo Pro Acoustic Monitoring system from Holroyd, part of Parker Kittiwake. Part of this undertaking was to employ a Condition Monitoring (CM) Technician to rollout the system across its sites.

The main driver for this initiative was to ensure WBL uses the best technology available to minimise any potential for unplanned production plant downtime. The necessity to minimise the risk of equipment failure and resulting impact on production led Whitworth Bros Ltd to devise a proactive CM strategy. They considered various monitoring options - such as vibration and temperature - and attended numerous trade shows, eventually discovering the MHC range of instruments from Holroyd, part of Parker Kittiwake.

WBL started collating data capture routes across all WBL sites and within a very short time, commenced data acquisition and analysis.

WBL recognise that: "The hardware and software associated with the Memo Pro system has been very well designed and constructed. It is portable, robust and straightforward to use. This functionality is mirrored with the analysis software, which allows new data to be quickly downloaded and compared against historic data for all machines detailed for each production area".

With data acquisition routes established, condition monitoring of the production critical plant commenced and this enabled WBL to take a proactive approach to monitoring and maintenance of the equipment at the company's Wellingborough and Peterborough sites.

The MHC-Memo Pro readily identified machines which were in need of remedial action and appropriate preventative maintenance was undertaken as required. Where machines were thought to be beyond routine servicing, these machines were withdrawn from service as part of planned maintenance activity. WBL devised a cost metric calculation to assess the savings to the company through the newly implemented CM activity. This approach is very beneficial in helping justify the expenditure and resource costs allocated to this particular CM strategy, as well as balancing the CM approach against that of machinery failure.

Proactive maintenance

Data collection takes place on a regular basis for all critical plant and machinery. This allows engineering resource to be directed to the plant in need of maintenance, and this is organised as part of planned, proactive activity, rather than as a result of a machinery breakdown.

WBL uses a suite of sensors that are compatible with the MHC-Memo Pro system. The standard magnetic mounted sensor is used to collect the vast majority of information with the hand-held, extended probe allowing data capture in hard-to-reach areas. Low-profile sensors have also been installed to allow critical plant data to be gathered. All three sensors are readily connected to the MHC-Memo Pro and data can be captured almost instantaneously.

Over the period of time that WBL has been using the equipment it has recognised that the MHC-Memo Pro is a robust, user-friendly and comprehensive tool. The data reduction and analysis software is well written, allowing analysis to be completed in an effective and timely manner.

WBL experience of the MHC-Memo Pro shows the following key benefits:

• Usability - its data collection method is straightforward and hardware easy to operate has excellent ergonomics and is very robust
• Intuitive - it does not require intensive training
• "(it) really is a turn-key solution. Data routes can be compiled readily, allowing important data to be gathered and analysis to be undertaken and completed promptly"
• Multiuser application - it offers good value as it can be used across different sites due to the multiuser applications

WBL currently carry out routine monthly data capture, supplemented with weekly collections for any machines suspected of having an underlying bearing issue. The Memo Pro is also used to take one-off readings to help correctly diagnose individual machine issues as they arise, thus reducing incorrect diagnosis of plant issues.

Current coverage at the Wellingborough site sees the collection of data spanning a staggering 2500 separate data points - and this ensures that a comprehensive dataset exists which allows machine condition trending to be completed. WBL recognise that the CM approach has significantly reduced the potential for unplanned production stoppages.

Existing coverage sees the majority of the Wellingborough site plant captured using the range of standard sensor products, so WBL are now looking at monitoring challenges they face with oscillatory equipment (flour sifters) and will be investigating technology that allows condition monitoring of these machines.

In collaboration with Holroyd, part of Parker Kittiwake, WBL will continue to monitor further advances in Condition Monitoring technology with a view to minimising future plant breakdown and maximising production efficiency across all its sites.

For further information about condition monitoring with the MHC-Memo Pro Acoustic Monitoring system go to www.kittiwakeholroyd.com.