Post Time：Apr 18,2025Classify:Industry NewsView：999
As glass bottles gain popularity in food and beverage packaging, manufacturers face increasing pressure to maintain seamless production. However, with rising demand comes greater risk of equipment failures and costly downtime. Addressing these challenges requires a proactive approach — especially when it comes to the motors that power production lines.
Unplanned downtime is more costly than ever. According to Siemens' 2024 report, "The True Cost of Downtime," heavy industry plants now lose 324 hours of production yearly, costing up to $182,000 per hour — totaling $59 million annually. A proactive maintenance strategy is essential to reducing these losses.
For glass bottle manufacturers relying on continuous production lines and conveyor-driven systems, equipment failures can have an equally disruptive and costly impact. However, by prioritizing preventative maintenance, companies can reduce unexpected failures, protect profitability, and maintain operational efficiency.
Motors power the conveyors, compressors, and assembly lines that run glass bottle production. Ensuring the optimal performance of these critical parts means taking measured steps to reduce failures and extend their lifespan.
A proactive approach to caring for the equipment you depend upon daily makes tremendous business sense. Deloitte reports preventative maintenance on manufacturing equipment can reduce unplanned downtime by 53%. Machine optimization leads to higher product consistency and 79% fewer defects.
Manufacturers can prevent some of the most common causes of motor failures in bottle production environments with preventative maintenance strategies that enhance motor reliability.
Glass bottle manufacturing’s high temperatures, abrasive particles, and caustic chemicals create extreme operating conditions for motors and related equipment. While motor failures can occur for several reasons, these five factors are among the most common:
Excessive heat and current draw: Glass production involves molten materials and high-temperature processing, subjecting motors to significant thermal stressors. Excessive heat accelerates insulation degradation, bearing wear, and motor winding failures. Overloaded motors exacerbate these problems by drawing more current than they can handle, leading to overheating and premature failure.
For instance, motors placed near glass furnaces often experience double exposure; they endure extreme heat from their environment and work harder under heavy loads. Without proper cooling and load balancing, these motors become prime candidates for failure.
Improper lubrication practices: Motor bearings rely on lubrication to minimize friction and wear. However, incorrect lubrication practices, such as over- or under-greasing or using incompatible lubricants, can cause significant damage. One glass plant experienced bearing seizure due to poor lubrication practices, resulting in a 36-hour production halt. The downtime led to thousands of lost units, proving that even minor maintenance oversights have costly repercussions.
Environmental contaminants: Glass manufacturing exposes motors to dust, silica, caustic chemicals, and moisture, leading to abrasion, corrosion, and insulation failure.
Neglected maintenance and inspections: Minor issues, such as unusual vibrations, abnormal noise, or slight overheating, often signal early-stage motor problems. Ignoring these warning signs can lead to critical failures, leaving manufacturers scrambling for costly emergency repairs while the line sits idle.
Voltage instability: Power surges, sudden fluctuations, and poor electrical grounding can damage motor windings, bearings, and insulation integrity. In one case, a glass molding facility suffered extended downtime after a voltage spike fried a key motor during a power restoration event. Without surge protection or voltage monitoring, these failures can occur without warning.
Preventative maintenance significantly reduces downtime risk. Facilities Dive reports that 65% of manufacturing professionals believe preventative maintenance is the most effective strategy for minimizing disruptions. However, while nearly 70% of manufacturers have these programs, many dedicate less than half of their maintenance time to these efforts.
To keep glass bottle production running smoothly, manufacturers should implement a structured preventative maintenance program with the following key components:
Scheduled, routine inspections to catch wear and tear early. Routine visual inspections of motor windings, bearings, and cooling systems can detect issues before they escalate.
Diagnostic tools like voltmeters to measure voltage imbalances, meggers to assess insulation integrity, and thermal imaging cameras to spot overheating components.
Lubrication should match operating conditions. Follow manufacturer recommendations, train teams on correct application, and remove excess grease to prevent overheating.
Glass manufacturers can safeguard motors from contaminants by:
Installing sealed enclosures to block dust and debris buildup.
Using cooling ducts or heat shields for motors in high-temperature areas.
Implementing humidity control to protect insulation from moisture damage.
Investing in real-time monitoring and predictive analytics significantly enhances manufacturing maintenance. For example, internet of things (IoT) sensors can track fluctuations in temperatures or early signs of vibration abnormalities due to load variations or other factors that signal a problem.
Keeping a stock of critical spare parts on hand ensures replacement components are there when you need them. Glass bottle manufacturers should work with trusted suppliers to help maintain inventory levels for essential components to reduce repair lead time.
A well-trained maintenance team can spot early warning signs, apply proper lubrication, and conduct routine diagnostics. Continuous training in failure detection, equipment handling, and safety protocols helps your in-house technicians address machine issues promptly.
A glass bottle manufacturer struggled with repeated motor failures, causing costly downtime. Partnering with their motor supplier, they implemented predictive maintenance using thermal imaging and optimized cooling enclosures. Within six months, motor failures dropped 40%, motor lifespan increased 30%, and repair costs fell. Their investment in prevention over reaction transformed a persistent problem into a sustainable solution—keeping production running smoothly and efficiently.
By prioritizing preventative maintenance, glass bottle manufacturers can significantly reduce downtime, improve production efficiency, and extend the life of critical equipment.
Taking proactive steps today will ensure a more reliable and profitable future. Start by evaluating your current maintenance strategy and identifying areas for improvement because, in glass bottle production, every minute of uptime counts.
Scott Saunders is the general manager of Motion & Control Enterprises' Piedmont Electric Motor subsidiary.
Source: www.foodmanufacturing.comAuthor: shangyi
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