Reduce Unplanned Downtime with Food & Beverage Asset Case Studies

Ammonia Compressor

Ammonia compressor maintenance is strictly regulated by agencies like OSHA. This asset needs to be monitored regularly, but route-based vibration monitoring is expensive and doesn’t tell the whole story.

  • $10,000/hour downtime cost
  • 4-24 hours downtime, on average
  • Risk of major health hazard

Bottle Filling Lines

Any delays at the filling step can impact production all the way down the line. Bottle filling lines contain a number of different assets and components, making it difficult to assess the overall health of the line.

  • Up to $40,000/hour downtime cost
  • 4-12 hours to repair or replace parts


These critical assets can be difficult to maintain, as homogenizers are often inaccessible due to guarding and have to process ever-changing mixes that impact their operating conditions.

  • $3,000/hour downtime cost
  • 4-8 hours to repair or replace parts

Cooling Towers

Multiple production processes can be shut down when a cooling tower can no longer efficiently dissipate excess heat. Rising temperatures threaten product integrity, adding the price of spoilage to the total cost of a failure event.

  • $1,000/hour downtime cost
  • $50,000 in equipment costs per failure
  • Upwards of $100,000 in cost savings for one failure avoidance

Dairy Homogenizers

Traditional vibration monitoring alone isn’t enough to catch dairy homogenizer faults before they become costly problems. Many process variables that can’t be captured by vibration analysis play a crucial role in this asset’s health.

  • $3,000/hour downtime cost
  • 4-8 hours to repair or replace parts

Industry leading data acquisition in high definition while achieving a total cost of sustainment 16x less than the average competitor.


customer savings

hours of prevented downtime

hours of monitoring

Optimize Your Food & Beverage Manufacturing Performance

Food and beverage producers can gain an advantage in one of the most competitive manufacturing industries by reducing unplanned downtime, diagnosing the root cause of machine failures, and achieving ideal operating conditions with the SMARTdiagnostics machine health optimization platform.

Download the 2022 KCF Guide to learn more about optimizing your manufacturing performance today.

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How Our Food & Beverage Machine Health Optimization Platform Works

SMARTdiagnostics, the software that powers our comprehensive machine health platform, allows thousands of individual monitoring points on your assets to wirelessly and continuously transmit machine health data to a central cloud database.

SMARTdiagnostics ingests signals from a range of sensor types — including third-party sensors — to detect early fault warning signals that vibration sensors alone won’t catch. Automated analytics capabilities put advanced machine health knowledge in your team’s hands from day one.

Solve Complex Asset Monitoring Challenges

Our machine health platform enables continuous monitoring of even your most difficult-to-reach assets. We’ve built sensors that are ideal for environments where lock-out tag-out requirements or guarding make other forms of monitoring impossible, that can withstand temperatures up to 257°F, and that can be fully submerged. Aggressive sampling intervals mean you’ll never miss an early fault signal that can lead to unplanned downtime.

Determine the optimal operating speed for your machine’s specific configuration using run-speed correlation capabilities. Wireless vibration sensors can be switched between multiple sampling frequency options at any time, allowing for analysis on both low and high-speed equipment.

Slower speed doesn’t always mean less damage — in one machine’s case, SMARTdiagnostics determined that a 15% reduction in speed caused a 300% increase in vibration

Detect Faults Earlier with SMARTdiagnostics

Our platform’s adaptive hardware is compatible with nearly any third-party transducer to wirelessly transmit data to the cloud, unlocking the potential for continuous remote monitoring of run speed, absolute and differential pressure, RMS current, oil quality, liquid levels, temperature, and more. We also offer ultrasonic monitoring that can detect imminent steam trap failures, leakage, early-stage bearing failures, low-speed bearing failures, and lubrication problems long before they can be picked up by standard vibration sensors.

KCF Technologies Gives Food & Beverage Manufacturers a Competitive Edge

Gain access to continuous monitoring and a team of engineers with a wealth of food processing industry experience in asset health monitoring, root cause analysis, and problem-solving.

Our holistic machine health optimization platform was designed specifically for manufacturers facing traditional machine health monitoring challenges. We’ll help you prevent unplanned downtime and increase productivity and revenue.