Case study · Food production
Custom monitoring built to assure quality, not just uptime.
A leading food producer came to Augos for pump maintenance. In consultation we found the real goal was quality assurance, so we built a tailor-made system that reads motor health and cold-store conditions every minute, and proves the pasteurisation was right.
- The client asked for pump maintenance. Through consultation the real need turned out to be quality assurance, so we monitored pump speed and efficiency to confirm the pasteurisation duration was right.
- A custom PCB reads motor temperature, current and vibration together, giving a cost-effective motor-health indicator without an expensive vibration rig.
- Wireless sensors log cold-store temperature, humidity and door state every minute, producing a tamper-proof record that stands up to food-safety and export audits.
From maintenance to quality assurance
Augos was approached by an industry-leading food producer with a specific problem: keep the pumps on their pasteuriser plant running. What began as a pump maintenance brief became something more valuable once we sat down with the team.
Through consultation it became clear the real goal was quality assurance. By monitoring pump speed and efficiency, a good general indicator of pump health, the client could confirm the pasteurisation duration was precise enough to deliver the required product standard for their pasteurised egg whites. That tied operational stability directly to the integrity of the final product.
Food producers here need auditable QA records for both local health compliance and international export. The system records every minute of cold-store and motor-health data as a tamper-proof digital log that stands up to a strict food-safety inspection, reducing the client's exposure to recalls or regulatory fines from a quality failure.
Sensor technology for precision QA
To meet the requirement without the cost of a traditional vibration-measurement rig, we built a custom solution:
- Custom monitoring hardware. A bespoke printed circuit board and software, with inputs for motor temperature, motor current and vibration. Together these give a highly effective, cost-efficient motor-health indicator for pump performance.
- Comprehensive cold-chain coverage. A network of wireless, battery-powered sensors measuring temperature and humidity in the cold stores, integrated with door open and closed sensors to prevent energy waste and hold precise temperature control.
All readings are captured every minute and sent to the Augos cloud platform for immediate insight.
Data-driven insight, built to grow
The platform turns the measurements into real-time monitoring and action:
- Real-time visibility. The team watches pump performance, motor health and door status as it happens.
- Integrated alerts. Alarms via SMS, email or WhatsApp give immediate notice the moment anything arises that could compromise product quality.
- Room to expand. The radio network makes it easy to add monitoring points, such as flow meters, to pin down the exact pasteurisation duration in future.
Sensing in this story
The tools behind the result.
Machine & industrial
Motor temperature, current and vibration as a health indicator.
Explore ›Environmental
Cold-store temperature, humidity and door state.
Explore ›Control & automation
Trigger alerts and actions when a reading drifts out of spec.
Explore ›The rest of Augos Sense
Air quality & safety
Particulates, gases and smoke, measured continuously wherever people work.
Explore ›Agriculture
Soil moisture, temperature and salinity, plus water level, flow and pressure.
Explore ›Commercial & industrial
Pressure, flow and level in pipes and tanks, plus gas and leak detection.
Explore ›HSE
The conditions that keep your people safe and your site compliant. Hardware being finalised.
Explore ›Proximity
Presence, position and occupancy across your sites. Hardware being finalised.
Explore ›Questions
Was the focus maintenance or quality assurance?
Quality assurance. The client first asked for pump preventative maintenance, but the deeper need was to prove product quality. By monitoring pump speed and efficiency we could confirm the pasteurisation ran long enough to guarantee the standard, linking machine behaviour directly to product integrity.
How does Augos monitor motor health without expensive vibration sensors?
With a custom PCB that reads motor temperature and current alongside vibration. Combined, these give an effective, cost-efficient motor-health indicator, avoiding the cost of a traditional vibration-measurement setup.
Does the data support food-safety compliance?
Yes. Every minute of cold-store and motor data is recorded as a tamper-proof digital log. That auditable record satisfies local health compliance and international export standards, and cuts exposure to recalls or fines from a quality failure.
Start small
Start with a single sensor.
No rip-and-replace and no commitment: a single sensor can be live in 48 hours, and you add more once it proves out. Sensors mount magnetically, with no wiring to run and no calibration to perform.
Augos Sense is priced in three parts: the sensors, priced per sensor by what each one is built to measure; connectivity, a monthly cost per sensor; and the platform, one charge per deployment. Figures on request: we size a quote, ex VAT, to the sensors and sites you need.
See what monitoring like this can do on your site.
Book a short call. Tell us what you need to watch, and we'll show you the sensor, the alerts and the control working on your own site.