From Alarms to Action: How A Dairy Separator Was Saved With MOVUS

Industry

Dairy/Food Processing

Asset

Separator

Technology

FitMachine

A Critical Asset at Risk

In dairy processing, precision is everything, and the high-speed separator is central to that precision. Spinning at 4500 RPM, this asset separates cream from skim milk to ensure fat content meets product specifications.

When a separator like this begins to degrade, the consequences can cascade quickly with inconsistent product quality, batch contamination, downstream process disruption, and significant unplanned downtime.

In this case, MOVUS FitMachine picked up early signs of abnormal vibration, with gradual deterioration unfolding over a six-week period. What began as minor deviations soon escalated to critical alarms. Thanks to continuous monitoring and real-time insights, the site team had the information they needed to act early before performance or product integrity were compromised.

What the Data Revealed

In March 2025, the FitMachine sensor on the separator detected a sharp and sustained rise in vibration levels. RMS readings spiked to ~16.9mm/s, more than eight times the asset’s normal baseline (1.5-2.0mm/s), and well above the ISO Class II alarm thresholds.

Analysis of the condition trend and FFT output suggested a combination of imbalance, misalignment and possible looseness or movement in the mounting. These faults, especially at 4500 RPM, posed a significant risk to the equipment’s structural integrity and surrounding process line.

Had the asset continued running in this condition, it could have led to a premature bearing failure, shaft or coupling damage, housing fatigue, or even contamination of dairy product batches. Following the alert, the site team inspected the machine and confirmed both looseness and imbalance. Early action prevented unplanned downtime and helped safeguard product quality.

The Payoff: Downtime Avoided, Value Unlocked

By surfacing early warnings well before failure, MOVUS FitMachine enabled the site team to step in before the issue escalated. What could have resulted in significant equipment damage, production loss, and emergency repairs was instead resolved through a timely inspection and planned response.

Given the high-speed nature of the asset, the severity of the vibration levels, and the critical role this separator plays in dairy processing, the cost of inaction would have been substantial. Here’s the estimated impact in real numbers:

Cost Category	Estimated Cost (AUD)
Bearing replacement + labour	$2,000 – $5,000
Unplanned downtime (4–12 hrs)	$8,000 – $24,000
Emergency repair premium	$2,000 – $4,000
Secondary equipment impact	$3,000 – $10,000
Batch/product loss	$5,000 – $15,000

Estimated Total Savings: $20,000-$58,000 AUD

From Alarms to Action: How A Dairy Separator Was Saved With MOVUS

Industry

Asset

Technology

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