IBIE - 2022 Special Edition & Show Preview - 61

IIOT
you have to air freight parts to the bakery. There's
a way to put an ROI on this because many sensors
are not expensive at all. "
Making sense of it all
Relying on sensors provides an affordable way to
monitor the lifeline of every major system in a bakery
at any given time.
" The latest advances in wireless sensor technology
allow users to begin collecting real-time data
without upgrading or modifying their existing control
package, " said Rowdy Brixey, president, Brixey
Engineering. " Vibration, temperature and cycle
counts are just an example of sensor offerings.
These sensors combined with the new analysis
software offerings can yield a host of useful predictive
data. "
On mixers, he noted, sensors track per unique
batch the gearbox vibration, amperage, voltage
and dough temperature - all key indicators about
how the system is running. The system uses historical
data to identify the early warning signs to
the maintenance crew.
" Code can be written to scrub the data and look
for signs of a problem, " Mr. Brixey said. " A bearings
vibration signature will start to change long before it
becomes noticeable to the hand, ear or eye. Properly
written code could see this pattern when vibration
is trending or spiking higher when loads are normal
or lower than expected compared to similar data
already collected for similar dough types. "
On large ovens, sensors could compare gas usage
to production pounds to indicate leaks or poor
system performance. Color meters can provide
control of bake temperature or time.
Training and security
While all of this technology holds a lot of promise,
it can create challenges for companies.
" The main barriers we see are understanding
data, No. 1. Cybersecurity would be No. 2, " Mr.
Izquierdo said.
He recommended that bakeries find a data partner
that fits their needs since they likely will have a third
party helping them process their data to identify
potential problems and opportunities to optimize the
process. He also said companies should ensure they
have a strong security system in place to protect
information and have a point person on staff who
understands data and can turn the information into
actions that benefit the business.
" That's really the trick, " Mr. Izquierdo added.
" How to look at all that information and get to the
next level. It's not about keeping your machines
running. It's about optimizing how they run. "
Using IoT for maintenance requires careful consideration
on several different levels, especially for
older bakeries and smaller ones. For example, does
a bakery's maintenance crew have the necessary
mechanical, electrical and other skills to maintain,
replace and repair sensors, touch screens and
human-machine interface panels when they break
down? Do these sensors and processing controls
create more maintenance work or complicate a
bakery's operation when they break down?
While digital technologies have become more affordable,
retrofitting legacy equipment must be evaluated
on a case-by-case basis. Any size bakery, even
a small one, can explore adding IoT to maintenance.
" Begin small and consider starting where you
see most of your 'unplanned events' taking place, "
Mr. Brixey advised. " It should be of no surprise that
by collecting more data you have a better chance
of determining the next failure before it happens.
Learn from this first introduction to IoT and capture
the savings before throwing more capital at
additional opportunities. "
*
DON'T MISS AT IBIE
Advances in Remote Maintenance for
Packaging Operations:
9:45 a.m. Sunday, Sept. 18
9:45 a.m. Tuesday, Sept. 20
W304
INSIDE IBIE | 61
The digital
transformation
of high-speed
bakeries allows
supervisors
to constantly
monitor
production in
real time.
Sosland Publishing Co.
IBIE - 2022 Special Edition & Show Preview

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