Although not a manufacturer, Penn Waste Inc. uses industrial automation technologies to operate and manage its recycling facility which processes more than 180,000 tons of material annually. And just like manufacturers, Penn Waste faces the problem of equipment downtime.
Recently, the company has begun to see its DRS glass breaker, used to separate glass from recyclable mixed ones, suffer premature failure. These failures were often attributable to the operating environment, where other recyclable items, such as coat hangers and wire bags, can become trapped in the bearings. Such equipment failures required manual intervention to correct and regular physical inspections to ensure optimal uptime.
“Often, several maintenance technicians would spend hours performing on-site inspections and cleaning debris from machines to reduce the risk of bearing failure,” says Sarah Torjman, senior marketing manager at Cassia Networks. “And when the bearings failed, additional manpower was required to investigate the severity of the problem, disrupting many of Penn Waste’s day-to-day business operations.”
To continuously monitor bearings in its equipment, accurately predict failures and avoid the need for manual inspections, Penn Waste has chosen to implement Cassia Networks’ X1000 Bluetooth gateways and IoT access controller along with ABB Ability smart sensors supplied by Dodge. Industrial.
Penn Waste has installed more than 60 Dodge smart sensors on the DRS glass-breaking machine to adequately cover all necessary bearings and gearboxes, says Torjman. In addition, two Cassia X1000 gateways were installed near the machine to continuously receive data from the sensors and send them to the cloud. These gateways are weatherproof and designed for outdoor use. They also feature Cassia Networks Pure Scan technology, designed to improve scanning capability in environments with high background noise and situations that require a lot of sensors.
“Cassia’s X1000 gateways provide long-range connectivity of up to 1000 feet in an open space and the ability to pair and connect up to 22 low-power Bluetooth devices simultaneously,” says Torjman. “Long-range connectivity and the ability to pair and link multiple sensors simultaneously were a key requirement for this implementation.”
Joe Wojciechowski, maintenance manager for Penn Waste, says, “Cassia’s X1000 gateways were simple to use and install and have withstood the test in these harsh environments. They provide the long-range connectivity we need. What you want from any wireless technology is reliability, efficiency and durability. Cassia’s gateways and Dodge’s smart sensors have given us just that. ”
According to Torjman, the process of installing and commissioning the smart sensors took less than three minutes. “Once the sensors were paired with Cassia’s gateways and a reliable internet connection was established, the gateways were able to send data to the cloud without interruption, giving Penn Waste the advanced tools they needed to access. to data at any time to proactively identify maintenance requirements and prioritize manpower tasks accordingly, ”says Torjman. “This gave Penn Waste the real-time visibility it needed to achieve its goals of reducing downtime and overall maintenance costs, while improving efficiency.”