An ear to the machine
Hans G. Hauri KG Mineralstoffwerke

About the customer

Hans G. HAURI KG Mineralstoffwerke is a stone processing company located in Bötzingen am Kaiserstuhl. HAURI specializes in the high-quality processing of mineral raw materials. The company operates three sites in the border triangle between France and Switzerland. The product range is versatile and is used in applications ranging from the construction industry to forestry, geothermal energy, healthcare or the environment. The Jura limestone of the Tuniberg is quarried at the Merdingen plant. In a complex technical process, the raw material is burned in the company’s own lime shaft kilns to calcium oxide, one of the most important products for environmental protection, waste water treatment, drinking water treatment, flue gas desulfurization and many more. Hauri is one of the most innovative companies in the industry, with state-of-the-art production facilities and its own research and quality laboratories.

Challenge

At the Merdingen site, the HAURI company operates a lime shaft kiln, the core of lime production. As is so often the case with essential production equipment, the question of its health is of crucial importance. Unplanned downtimes are not only expensive and have a great influence on the subsequent processing steps. Not all components of complex technical equipment can be kept in stock, so that spontaneous procurement can become an enormous challenge. The aim is to recognize the incipient damage in good time in order to avoid unplanned downtimes and to procure spare parts and replacement equipment as required.

Am Standort Merdingen betreibt die Firma HAURI einen Kalkschachtofen, das Kernstück der Kalkherstellung.

With the continuous monitoring of the kiln, I always have an ear to the machine and can react at any time. We have already discovered and been able to optimize many minor problems through monitoring alone.

Dipl. Ing. Rainer Zwick - Technischer Leiter

Solution

HAURI has decided to monitor the condition of its production equipment more closely with the introduction of the Condition-based Maintenance (CBM) cockpit from RODIAS GmbH. The decisive advantage is that the state of health is continuously shown. The maintenance worker always has his “ear to the machine”, so to speak. If deviations occur, warnings and alarms are automatically triggered in the cockpit.

The low-threshold integration of maintenance-related sensor data is a novelty and enables a quick start into predictive maintenance. The CBM Cockpit detects imminent wear of equipment and changes in condition by means of vibration analysis. Violation of warning and alarm limits automatically generates orders and recommendations for action.

HAURI hat sich dazu entschieden, mit der Einführung des Condition-based Maintenance (CBM)-Cockpits der RODIAS GmbH den Zustand ihrer Produktionsanlagen genauer zu überwachen.

Benefit

With the introduction of the CBM Cockpit, HAURI is able to detect the wear of critical components on the lime shaft kiln at an early stage and can thus react in time before the plant fails. The CBM cockpit also enables learning from the recorded data and thus elucidating the causes of damage. As a result, future damage and the resulting failures can be avoided. The planning of maintenance measures is made more reliable by the new system and has a favorable effect on the utilization of remaining running times. Inventory management in particular benefits from needs-based planning in terms of provisioning, space and costs. All in all, the introduction of the Condition-based Maintenance Cockpit has led to a reduction in downtime, cost savings through early detection of problems, and greater confidence in the health of the equipment.
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