Can Filler Condition Monitoring
Vibration and condition data trended in Ignition with threshold alerting, giving the maintenance team early warning of developing filler faults.
Scope & approach
The can filling line at Remedy Drinks is a production-critical asset. Unplanned downtime on the filler directly affects output and shelf availability. Metromotion Controls was engaged to implement a condition monitoring solution that captured vibration and operational data from the can filler, providing the maintenance team with early indicators of developing faults. The solution used an MQTT-based data collection architecture to feed condition data into Ignition, where it was trended and threshold-monitored alongside production events.
What was delivered
- Vibration and condition data from the can filler was captured and trended in real time within the existing Ignition platform.
- Threshold-based alerting gave the maintenance team early warning of developing faults on the filler.
- The MQTT architecture provided a reusable connectivity pattern for extending condition monitoring to other assets on site.
Scope items
- Condition monitoring sensor installation and MQTT data collection architecture for the can filling line
- Ignition integration for real-time condition data display, trending, and threshold alerting
- Alert configuration aligned to maintenance inspection intervals and fault thresholds
- Implementation documentation and handover support for ongoing site management
Services and sectors behind this work
Plant Intelligence: factory data and OEE
OEE, reports, quality, CIP, maintenance and energy data from the team that builds and programs the lines.
OT networks and industrial networking
OT network design, industrial Ethernet, secure remote access and SCADA server connectivity.
Food and beverage automation Australia
Automation, traceability, CIP, SCADA and production data for Australian food and beverage plants.
IIoT and condition monitoring
Condition monitoring to ISO 17359 and ISO 13374, the P-F curve, MQTT and OPC UA data acquisition, and how condition data ties into OEE.
Remedy Drinks MEX CMMS integration
Ignition to MEX integration generating automatic work orders from plant events for a beverage producer.
OEE and production monitoring
Live OEE, line status and stop reasons read directly from the PLCs on food and beverage lines.
Maintenance from plant data
Plant events that raise CMMS work orders, condition alerts before a stop, and runtime counts for preventive maintenance.
Ignition SCADA integrator Melbourne
Ignition Gold Certified System Integrator for Ignition SCADA, historian, reporting and MES functions.
Preventive maintenance from machine data
Runtime hours, cycle counts and condition data as the basis for maintenance intervals.
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