Kraft Heinz is known worldwide for its operational excellence. One of its plants in Brazil stands out as a key production hub with its own tomato processing operation. To keep driving results, the team needed to level up their maintenance strategy and eliminate recurring losses tied to motor failures.
The Challenge
In 2023, the plant spent over $125,000 on corrective maintenance for electric motors. Breakdowns caused unplanned downtime, impacted asset availability, and increased logistics and repair costs. The team needed a way to anticipate failures and boost equipment reliability without overloading technicians with extra work.
The Solution
Starting in January 2024, Kraft Heinz implemented Tractian’s real-time monitoring sensors on their most critical motors, including multiple units over 100 horsepower. These sensors track vibration, temperature, and RPM 24/7, detecting abnormalities and signs of failure before they escalate into bigger issues.
Proof Point: From Detection to Action
On a weekend, one technician received a high-temperature alert (120°C - 248° F) from a 150 HP motor responsible for tomato concentration. Even though he was off duty, he notified the team right away. Upon inspection, they found a loose fan and fixed it before damage occurred. The issue was resolved quickly, avoiding a major failure and reinforcing the team’s confidence in using data to guide their actions.
Impact and Outcomes
Real-time monitoring delivered measurable outcomes for Kraft Heinz:
- 53% reduction in corrective maintenance spending on electric motors
- More than 1,000 hours of downtime avoided
- 100% uptime for all monitored critical motors
- The savings from Tractian allowed the team to invest in a new internal motor rewinding room, improving their ability to handle future maintenance in-house
