Danish Crown: Avoiding Critical Machine Breakdowns and Downtime with Siana

Transforming Food Processing with Predictive Maintenance

In the food processing industry, where production continuity is a key factor for operational success, maintaining machinery in optimal condition is crucial. Danish Crown, a global leader in meat processing, consistently seeks innovative ways to ensure its operations run smoothly and efficiently. 

This case study spotlights Danish Crown's strategic move to enhance operational reliability and minimize downtime by integrating Siana's cutting-edge Predictive Maintenance technology, to monitor rotating equipment, including Motors, Gear Motors, Decanter Centrifuges and more. 

With Siana's technology, Danish Crown's facility has avoided
critical machine breakdowns, leading to reduced unplanned
downtime, heightened productivity, and millions
in cost savings!

The Challenge of Reducing Unplanned Downtime

Danish Crown’s capacity to process 20,000 pigs daily, at its manufacturing facility in Horsens, Denmark, demands relentless operational precision and machinery reliability. However, like many large-scale manufacturing operations, the facility faced challenges related to unplanned machinery downtime, which can have significant repercussions, including production delays, increased labor costs, and reduced product quality. Recognizing the need for a more proactive approach to machinery maintenance, Danish Crown sought a solution that could predict and prevent potential failures before they disrupted production.

Ensuring Uninterrupted Operations with Siana

Siana's predictive maintenance system was implemented at Danish Crown's facility to address these challenges. This system can monitor rotating machines, such as motors, pumps, bearings, compressors, gear boxes etc., and automatically predict failures and breakdowns before they occur. What sets Siana apart is its high degree of usability and autonomy, making it accessible to maintenance technicians without specialized knowledge in the field, and giving them the ability to proactively monitor the health of their machinery.

Implementation in no time, with minimal effort!

Implementing Siana's technology at the facility was a straightforward process. Maintenance staff were able to install the Siana Devices on critical machinery and connect them to the Siana Platform without the need for extensive training or technical expertise, through the use of the Siana App. The Siana Platform provided a convenient interface for monitoring the status of all machines, while enabling notifications ensured that the maintenance staff was always aware of any machine-related issues.

Success Stories: Predicting and Preventing Failures

• Conveyor Gear-Motor: A crucial conveyor gear-motor, essential for transporting pigs within the facility, was identified for impending failure on July 5, 2023. Recognizing its critical role, maintenance scheduled a replacement during a planned production halt on July 9, 2023, thus preventing a complete production stop.

• Decanter Centrifuge: This vital machine, used for separating animal fat and protein, showed signs of failure detected by Siana on November 8, 2023. Given its importance and complexity, a specialized maintenance team serviced it on November 19, 2023, replacing a bearing and adding oil during already scheduled downtime.
  
  
  

  

Clear Benefits from using Siana Predictive Maintenance

The introduction of Siana's predictive maintenance system has brought about substantial benefits for Danish Crown:

• Reduced Unplanned Downtime: Early detection of potential failures allowed for scheduled maintenance, preventing unexpected breakdowns and ensuring continuous production.
  
  

• Enhanced Productivity: The maintenance team can schedule repairs and maintenance work without disrupting the production schedule, optimizing the facility's overall efficiency.
  
  

• Cost Savings: By minimizing unplanned downtime, the facility has avoided costly repairs and associated production losses, contributing to improved profitability and operational efficiency.
  
  

• Ease of Use: The system's intuitive design and usability ensured that Danish Crown's regular maintenance technicians could install and utilize the technology without the need for extensive training, embodying Siana's commitment to usability and autonomy.
  
  

• Improved Maintenance Workflows: Maintenance staff can now prioritize their work based on predictive insights, focusing on machinery that poses the highest risk of failure, thus improving overall maintenance efficiency.

  
  

"We use Siana to monitor several different components, such as motors and gear motors. Through the use of the system, we have averted multiple sudden breakdowns, thereby avoiding costly downtime. We find the system to be both clever and intuitive, because it’s really easy to get started with and use in connection with our daily maintenance work."

TPM Planner, Danish Crown A/S
Henrik Jakobsen

A Successful Collaboration

The collaboration between Siana and Danish Crown showcases the transformative impact of innovative technology like Siana's predictive maintenance system in the food processing industry. Danish Crown's successful implementation of Siana demonstrates the system's potential to revolutionize maintenance strategies, highlighting the importance of proactive measures in optimizing productivity and reducing costs.