Case study · Foundry · Predictive maintenance
A vibration alert on a sand-mixer gearbox avoided a failure estimated at about ₹50 lakh.
Evidence: Measured alert · about ₹50 lakh failure avoided (client-validated estimate)
- Industry
- Foundry
- System
- Sand-mixer gearbox
- Data used
- Vibration sensor, maintenance inspection log
below 3 mm/snormal vibration
above 12 mm/salert reading
about ₹50 lakhfailure cost avoided, one time (estimate)
What was found
Gearbox vibration spiked past 12 mm/s. Its normal reading sits below 3 mm/s.
What was done
The gearbox was flagged for inspection immediately and serviced before it seized mid-campaign. A replacement quoted at about ₹50 lakh became a scheduled afternoon’s work.
Cost and benefit
| Normal vibration | below 3 mm/s |
|---|---|
| Alert reading | above 12 mm/s |
| Failure cost avoided | about ₹50 lakh, one time |
More case studies
- Food processing · Compressed air
A quarter off compressor energy.
491.77 to 368.25 kWh a day, from a zero-cost change to compressor sequencing.Measured on the compressor feeder · about ₹3.01 lakh a yearRead the case study
- Food processing · Power factor
A repaired capacitor bank, measured on its own feeder.
Daily feeder energy fell from 199.94 to 60.87 kWh after the repair.Measured on the feeder · about ₹3.43 lakh a yearRead the case study - Sugar cogeneration · Early warning
A turbine gearbox heading the wrong way, about two years early.
Bearing vibration crept up all year while every reading stayed inside the ISO good band.Measured trend · early warning, no saving claimedRead the case study
See it on your own plant.
No monitoring yet?
Zerowatt Vitals
Zerowatt Vitals puts every meter, sensor and machine in the facility live on one platform. Start with one system and add the rest as you go.
Already have monitoring?
Zerowatt Digital Brain
Zerowatt Digital Brain works on your existing monitoring system, DCS, SCADA or historian. Share your historian data and get your findings report.
zerowatt.energy · [email protected] · +91 80313 39988