Feed Mill Bearing Fault Detected Before Failure

Working to Achieve

AVT Reliability® supports the site in achieving a more reliable and predictable operation through condition-based maintenance, using the Machine Sentry® platform to identify developing faults, reduce unplanned downtime, and provide maintenance teams with sufficient time to plan repairs.

The Challenge

The monitored asset formed part of the feed production process and was located above the press motors used in pellet manufacturing.

The equipment plays an important role in the conditioning process, where steam and liquids are mixed with product prior to pressing to improve pellet durability and quality. An unexpected failure of the asset would have resulted in production disruption, increased maintenance costs, and potential delays while replacement components were sourced and installed.

Our Approach

AVT Reliability® carries out monthly condition monitoring surveys across critical assets on site using the Machine Sentry® platform. During each visit, vibration data is collected and analysed to identify changes in machine condition before failure occurs.

This proactive approach enables maintenance teams to schedule repairs during planned maintenance windows and avoid costly reactive interventions. Alongside vibration analysis, AVT engineers carry out visual and audible inspections to identify signs of deterioration that may not yet be evident in the data alone.

Our Findings

During a routine condition monitoring survey in August 2025, an AVT engineer identified a noticeable change in the asset’s vibration behaviour. Acceleration levels had increased and breached established alarm thresholds for the first time since monitoring began.

While carrying out the inspection, the engineer also detected an abnormal bearing noise despite the challenging acoustic conditions within the production environment. Further analysis of the vibration data indicated developing bearing wear within the motor. The findings were discussed with the site contact, and an Action Note was raised through the Machine Sentry®

The Solution

Following notification from AVT, the site elected to replace the motor with a new unit. Once installed, AVT collected a new baseline dataset and continued routine monitoring of the asset. The replacement successfully eliminated the fault condition, and the asset returned to normal operating parameters.

Follow-Up

Subsequent monitoring visits confirmed a significant reduction in acceleration levels and a return to stable operating condition. The new baseline readings established a healthy reference point for future monitoring and demonstrated that the corrective action had successfully resolved the issue. Had the defect gone undetected, continued bearing deterioration would likely have resulted in an unexpected failure, increased maintenance costs, additional labour requirements, and avoidable production downtime.