No Magic Wand Needed

To describe the operating environment for the customer’s motors as challenging would be an understatement. After every shift, the production line assets are subjected to a rigorous wash-down using high-powered water jets. 

Whilst previous engineers had tried to keep on top of the situation with nothing more than maintenance, repair and replacement of failed assets, when ERIKS won an Asset Management contract with the customer their first step was to look at the bigger picture. 

The dry facts 

ERIKS’ analysis revealed that the majority of motor failures at the site were directly related to water- or moisture-ingress to electrical assets. Since the frequent wash-downs are a non-negotiable part of the production process, the issue was how to reduce or eradicate the amount of water coming into contact with electrics. 

This didn’t need a radical re-think or a miracle cure. All that was required was a clear-sighted review of the assets and some engineering Best Practice. 

ERIKS’ North-West Regional Hub was the local facility with the know-how and resources to carry it through.

Upping the IP

The first step was clearly to improve the IP rating of the existing assets wherever possible. 

ERIKS’ engineers examined all the motors, using their experience to identify all the likely points of water ingress. They then optimised their ingress protection by – for example – replacing standard gaskets with rubber, installing double seals and lip seals on drive shafts, and sealing other potential points of entry for water or moisture, using silicon or other products.

Of course in all cases they were aware of the need to use only food-safe products in areas where there was any risk of product contact. 

For some of the most vulnerable motors and gearboxes, ERIKS installed food-safe covers to provide complete protection against water ingress. For others, the assets were upgraded to replacements with a higher, IP55 rating, defined as: “water projected by a nozzle against the enclosure from any direction shall have no harmful effect.”

In addition, terminal boxes – often the most vulnerable point for water ingress – were treated with epoxy resin to maximise their water protection. 

Engineering and education

Alongside the engineering initiatives which helped to improve the ingress protection of the assets, ERIKS’ engineers identified the need to educate the cleaning teams on the use of jet washers during wash-downs. 

As part of this process, ERIKS’ staff worked alongside the nightshift to help operators and cleaners understand the need for greater care during wash-downs, and to advise them on how to achieve the same levels of cleanliness without forcing water unnecessarily into vulnerable areas of equipment.

As a result of all these initiatives and actions, ERIKS succeeded in reducing the percentage of motor failures associated with water ingress from 50% a month to 6%. This not only reduced maintenance and repair costs – helping to lower the Total Cost of Ownership of the assets – but also optimised motor reliability, and increased productivity by reducing downtime. 

The X Factor

The successful outcome was thanks to a combination of factors. Firstly, ERIKS’ experience, which enabled the engineers to establish the root cause of the failures. Secondly, ERIKS’ know-how, which led to cost-effective solutions. Thirdly, the “X” factor: ERIKS’ willingness to think outside the box and go the extra mile.

Repeatedly repairing failed motors or replacing them with identical models simply addressed the cause, not the effect. Taking a wider view enabled ERIKS to find a more lasting solution. And being prepared to step outside a basic engineering remit, working to educate operators and cleaners on best practice, for example, also helped to ensure that everything possible was done to resolve the issue for the customer.