We offer preventive and predictive maintenance services aimed at identifying potential issues before they impact operations. These services include condition assessment, performance checks, and maintenance support to help reduce unplanned downtime and extend equipment life. Our approach is practical and data-driven, supporting informed maintenance planning and reliable plant operation.
Screw and Barrel Measurement: Wear in the processing section of a twin-screw extruder can affect performance and product quality. We carry out internal and external wear measurements using Mitutoyo measuring instruments, covering diameters from 20 mm to 300 mm. These measurements help identify wear patterns and possible causes, supporting informed decisions on screw configuration and appropriate material of construction (MoC).
Industrial Endoscope Inspection: We use an industrial endoscope with recording capability to inspect internal areas of equipment such as gearboxes and barrels through available inspection openings. The recorded footage allows for off-site review and comparison over time. When required, this is complemented with additional diagnostic tools, such as acoustic monitoring, to support condition assessment and maintenance planning.
Vibration monitoring is an important parameter for assessing the condition of extruder motors, gearboxes, and pumps. Using SKF vibration measurement tools, we assess vibration levels to support condition evaluation of key extrusion line components. Vibration analysis supports preventive and predictive maintenance by helping identify developing issues at an early stage.
To complement vibration measurements, we use an industrial stethoscope to monitor noise in the audible range for comparative assessment. This combined approach supports improved condition monitoring and maintenance planning.
Thermography is used as a diagnostic tool for assessing both mechanical and electrical conditions within a plant. Using SKF thermography equipment, we capture temperature profiles of critical components to support condition monitoring and maintenance planning.
The non-contact nature of thermography allows temperature measurements to be taken safely from a distance, including in hard-to-reach areas. This supports the assessment of bearing temperatures, heating and cooling behaviour in processing zones, and identification of abnormal temperature patterns. Thermography is also used to detect electrical issues such as localized heating in cables, terminals, and contactors.
By identifying temperature deviations and hotspots at an early stage, thermography supports preventive and predictive maintenance activities, helping reduce the risk of unplanned downtime and supporting safe and reliable plant operation.
Oil filtration is used to remove contaminants such as dirt, moisture, and wear particles from lubricating oil used in machinery, gearboxes, and hydraulic systems. Contaminants introduced through component wear, environmental exposure, or operating conditions can degrade oil quality and affect equipment reliability.
We support oil filtration as part of condition-based maintenance by assessing oil condition and applying filtration solutions to improve oil cleanliness. Effective oil filtration helps maintain lubricant performance, protect mechanical components, and extend oil and equipment service life.
Oil filtration supports preventive maintenance by reducing wear-related failures and supporting reliable operation of rotating and hydraulic equipment.
Transformer Sizing: We support electrical system planning through accurate transformer sizing based on assessed load requirements and operational conditions. This ensures that the electrical infrastructure is appropriately rated to support reliable and safe power distribution.
Single Line Diagram (SLD) and Distribution System: We develop Single Line Diagrams (SLDs) and assist in the planning of electrical distribution systems. This includes defining cable specifications, schedules, and routing layouts to support efficient power distribution and coordinated system design.
Complete or Partial Automation: We provide support for complete or partial automation systems, depending on project requirements. Our involvement includes automation concept development, system integration support, and enhancement of existing automation to improve operational control and process consistency.
Laser alignment is used to accurately align rotating equipment such as extruder main motors, gearboxes, pumps, and auxiliary drives. Compared to conventional dial gauge methods, laser alignment tools enable faster setup and improved measurement accuracy, supporting reliable alignment results.
Proper alignment plays an important role in reducing vibration, minimizing wear, and supporting the long-term reliability of rotating equipment. Even small misalignments can contribute to increased mechanical stress and premature component wear. Through laser alignment, we support precise positioning of connected equipment to meet recommended alignment tolerances.
Laser alignment supports preventive maintenance by improving equipment reliability, reducing unplanned downtime, and supporting consistent operational performance. This service forms an important part of condition-based maintenance and equipment health management.
Ultrasonic testing is used for bearing condition monitoring and leak detection across plant utility and process systems. Using the UE Systems Ultraprobe 10,000, we detect high-frequency sound signals associated with bearing wear, lubrication issues, and early-stage defects. This supports condition assessment and maintenance planning before faults develop into failures.
The same ultrasonic technology is used to detect air and gas leaks in systems such as compressed air lines and utility networks. By identifying leak sources accurately, ultrasonic inspection supports corrective actions aimed at reducing losses and improving system reliability.
Bearing and leak analysis forms part of predictive maintenance activities, supporting improved equipment reliability, reduced unplanned downtime, and informed maintenance decisions.
Motor and gearbox inspection, repair, and overhaul form an important part of maintaining reliable operations in polymer processing plants. We support these activities using specialised tools such as hydraulic pullers, hydraulic pumps and cylinders, and bearing induction heaters to enable controlled disassembly, inspection, and reassembly of components.
Motor condition assessment is carried out through standard electrical tests, including insulation resistance and winding resistance measurements, to evaluate motor health and identify potential deterioration at an early stage. These assessments support maintenance planning and corrective actions before failures occur.
Our service scope includes inspection, breakdown maintenance, predictive maintenance support, and complete overhauls of motors and gearboxes. We also support repairs involving damaged bearings, shafts, and gears, as well as timing and alignment activities using appropriate hydraulic equipment to meet operational requirements.
Through a combination of proper tooling, condition assessment, and structured repair processes, we support the reliable operation and service life of motors and gearboxes used in polymer processing applications.
We use the Megger MTR105 rotating machine tester to assess the condition of low-tension (LT) motors as part of motor inspection and condition monitoring activities. The tester enables measurement of insulation resistance, winding resistance, capacitance, inductance, and rotation parameters within a single test setup.
These measurements support evaluation of motor windings, connections, and overall electrical condition, helping identify deterioration or abnormalities at an early stage. Rotating machine testing supports informed maintenance planning and contributes to improved reliability of LT motors.