One of Unilever's plants in Latin America runs food production lines around the clock. In 112 days of continuous monitoring across critical assets, the team prevented 19 failures, avoided 117 hours of unplanned downtime, and protected over $796K in corrective costs. The following quarter, scope expanded to a second wave: 24 more anticipated failures.
Operational challenges
This plant produces high-demand brands like Knorr and Hellmann's, with WET lines, elevating screws, vacushears, and process pumps that cannot stop. Before Tractian, reliability depended on scheduled inspections and manual vibration analysis. Measurements were intermittent: between one visit and the next, assets kept running with no visibility into their actual condition.
Implementation
Deployment began in June 2025 with condition monitoring sensors to keep track of real-time vibration and temperature, installed on the highest-risk assets. Tractian's Customer Success team worked on-site alongside the maintenance team to prioritize coverage, validate technical data sheets, and train shift personnel.
- 40 critical assets covered
- 320 sensors installed
- 100% of sensors online throughout the period
- 100% of insights verified in the field
- Areas monitored: KSM, Syrup, Vacushears, Knorr WET, Effluents, and blower motors
Q2 2025 Results
In 112 days, the platform detected 34 events across critical assets. 79% were resolved through intervention before escalating to functional failure.
Critical failures prevented
Three Q2 interventions account for the bulk of protected value across rotating assets.
| Asset | Failure detected | Finding | Hours | Cost avoided |
|---|---|---|---|---|
| KSM · Tank 02 |
Mechanical looseness | Wear on the tank bottom bushing, no free shaft rotation. Bolts secured and replacement scheduled. | 24 | $250K+ USD |
| Syrup · Elevating Screw |
Temperature above limit | Bearing wear. Replacement of bearings, seal, and 3/8 packing gland. | 8 | $200K+ USD |
| Vacushear 2 · Oily |
Temperature above limit | Bearing wear confirmed on inspection. Replacement before impacting production. | 8 | $135K+ USD |
What’s next
Monitoring expanded to Knorr and Effluents. In 90 additional days, the team logged 24 more anticipated failures: misalignment in Effluent pumps, cavitation, and worn bearings in Knorr WET agitators. Coverage began reaching assets previously considered blind spots. Next: refining technical data sheets with key plant users, strengthening training in Hellmann's, Effluents, and new areas, and deploying a new sensor round, bringing the total to 520.
