Success Story: Early Detection in Action at Amcor Flexibles
A collaboration between Erbessd Instruments and Regnus Engineering Solutions.
Introduction
At Erbessd Instruments, we believe success starts with early detection. This success story highlights how our technology, in partnership with Regnus Engineering, helped Amcor Flexibles prevent failures, reduce risk, and build confidence in proactive maintenance practices — even on newly installed machinery.
Client overview
Amcor Flexibles – Packaging Material Coating Facility.
Location: Gebze, Turkey.
Partner: Regnus Engineering Solutions.
Date: March 25, 2025.
Project Lead: Eray Engin, ISO-CAT-2 Certified.
Background
Amcor Flexibles raised concerns about unusual noise from a new air compressor only two months into operation.
While the manufacturer attributed it to a lack of lubrication, Amcor requested a second opinion from Regnus Engineering to validate the root cause and avoid potential costs during the warranty period.
Regnus Approach
Regnus emphasized that early-stage mechanical issues can affect even brand-new machinery, citing potential mounting, alignment, and manufacturing faults.
Using the ‘Bathtub Curve’ model, they recommended proactive condition monitoring to catch failures early.
Equipment Setup
– Compressor Power: 110 kW.
– Speed: 1470 RPM.
– Operation: Variable Speed.
– Sensors: Phantom Gen-3 at four points.
– Communication: Gateway-2, Ruth241, EI-Analytic.
– Total Installation Time: 20 minutes.
– Monitoring Period: March 25 – April 10, 3x/day.
Analysis Highlights
Motor Non-Drive End:
– Vibration: 2.80 mm/s (below ISO limit)
– Mechanical looseness and waveform distortion observed.
– Low lubrication suggested by ground noise.
Motor Drive End:
– Vibration: 1.40 mm/s (within safe range)
– Looseness and dry bearing indicators noted
Compressor Drive End:
– Acceleration: 3.81 g (alarm threshold)
– Stage 2 bearing failure indicators
– Bearing replacement recommended under warranty
Compressor Non-Drive End:
– Acceleration: 2.4 g (under alarm limit)
– Stage 1 bearing failure indicators
– Warranty action recommended
Summary and Recommendations
– Replace front and rear compressor bearings.
– Fix looseness in motor bearings.
– Lubricate to eliminate ground noise.
Results and Impact
– Amcor saw clear benefits from Phantom and EI-Analytic solutions.
– Prevented repair costs and service disruptions.
– Customer plans budget for full project next year.
– Moving toward hybrid service for high-criticality assets.
Contact
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