Project Profiles

AS-I TETRA PAK PROJECT

Installation of AS-I ProcessLine Module and Addressing of 39 valves and projection to the AS-I Master. This system reduces complexity in wiring and installation and improves data collection and process management.

Installed Instruments:

• 5 Pcs. AC2*** – AS-I ProcessLine Module
• Application :
• Industry : Food & Beverages

LEVEL TRANSMITTER

The client wants to monitor the tank level, so we recommended the Level Transmitter (LR series) for monitoring the water levels in the chiller water tank if its high or low. The data output is directly integrated to their siemens PLC

Installed Instruments:

• 2 Pcs. LR*** – Level Switch
• Application: Water Level Monitoring
• Industry : Water

CAMERA SENSOR

Installation of a Camera Sensor for the twin conveyor system. This project aims to monitor crates for underfill and overfill conditions. When the Camera Sensor detects an underfilled or overfilled crate, it will trigger the rejection system to remove the defective case.

Installed Instruments:

• 2 Pcs Camera Sensor
• Application : Missing Bottle
• Industry : Brewery

TRAINING AND DEMONSTRATION

Costumer receive a thorough understanding of the features, functionality, and capabilities of the product through training and demonstrations. Customers can witness the product in use, which makes it easier for them to understand its benefits and possible uses. Purchase in advance of each of the instruments listed below. First quarter 2024 would be the implementation date.

Installed Instruments:

• 60Pcs LR2*** – Level Sensor Water tank application
  60Pcs MVQ*** – Smart valve sensor
  60Pcs SA5*** – Compact Flow sensor water consumption
  1 Set VSA*** – Accelerometer
  Industry : Battery

AS-I SYSTEM

The AS-i System is supplied and installed in the food and beverage plant. The food and beverage industry may automate both simple and complicated processes at a reasonable cost by using AS-i technology. It will lessen the requirement for costly, extensive wiring. Being considerate to customers means imparting our knowledge to the system.

Installed Instruments:

• AC2***
• AC14**
• Alfa Laval AS-I Valve
• Industry : Food and Bev

VIBRATION SENSOR

The installation and supply of vibration sensors to ammonia compressors promotes preventive maintenance, safety, and operational effectiveness, which lowers costs and extends the life of the machinery.

Installed Instruments:

• VNB*** – Vibration Transmitter
• Application : Condition Monitoring for NH2 Motor
• Industry : Beverages

VIBRATION SENSORS

The provision and installation of vibration sensors enable the early detection of anomalies or irregularities in machinery, enabling the timely detection of possible problems before they worsen. Early detection reduces downtime and production interruptions by preventing equipment breakdowns. In the end, this helps the business save a lot of money.

Installed Instruments:

• VSA*** – Accelerometer
• Application: Dryer Motor
• Industry : Foods

PRESSURE SENSORS

Installing a pressure sensor gauge gives industrial processes real-time information about pressure levels. This makes it possible to precisely regulate and modify the manufacturing processes in order to preserve ideal circumstances and product quality. It is possible to promptly detect and handle possible problems or deviations by keeping an eye on pressure levels.

Installed Instruments:

• PG*** – Flush pressure sensor with analog display
• Application: Water Pressure monitoring
• Industry : Food and Bev

PRESSURE SENSORS

Installing a pressure sensor gauge give industrial processes real-time information about pressure levels. This makes it possible to precisely regulate and modify the manufacturing processes in order to preserve ideal circumstances and product quality. It is possible to promptly detect and handle possible problems or deviations by keeping an eye on pressure levels.

Installed Instruments:

• PG*** – Flush pressure sensor with analog display
• Application: Water Pressure monitoring
• Industry : Food and Bev

FLOW SENSOR

The Flow Sensor is installed. Sustaining precise flow rates is essential to guaranteeing the product’s quality and consistency. By avoiding changes in numbers that can have an impact on the product’s qualities, it helps with quality control. By installing a Flow Sensor, one may precisely manage the qualities of the product by monitoring and controlling the flow rates.

Installed Instruments:

• SA**** – Flow Sensor
• Application: C3-C5 Water consumption
• Industry : Foods

TEMPERATURE SENSOR

Monitoring temperature directly on the motor projects internal components from excessive heat. This protection extends the motor’s lifespan by preventing premature wear degradation due to overheating. The customer purchased the components and helped them to integrate the IO System to the PLC., ensuring efficient and reliable temperature monitoring of the motor:

Installed Instruments:

• TN7*** – Temperature Sensor
• Industry : Cement

MINERALS

After the successful replacement of the old AS-i Master AC1375 with the advanced AC1411, our customer has once again chosen to partner with us

– purchasing both item and our service. This repeat the trust highlights not only the proven reliability of the system but also our team’s expertise in delivering seamless AS-i solutions.

One of the challenges we encountered was that the LCD display of the AC1375 was no longer visible, making it difficult to identify the existing node addresses. Although the customer had a diagram, but it was not updated, which further added to the complexity. Nevertheless, our team was able to successfully trace and determine the correct node addresses of the existing AS-i master, ensuring a smooth migration to the new AS-I Master.

FOOD AND BEV INDUSTRY

Last year, we proudly completed the successful commissioning of the AS-i system for Flavour Tanks 1 and 2, seamlessly controlling a total of 109 valves. This year marks another milestone with the successful commissioning of Flavour Tank 3, now efficiently managing 62 valves – a testament to our continued commitment to reliable solutions and customer success.

Challenges Encountered 

• Difficulty in isolating the fault between the AC2900 module and the Alfa Laval ThinkTop valve head.
• Although the AS-i power supply and master appeared normal, connecting one valve caused multiple nodes to report as Missing Slave or faulted.
• Using the Ac1154 addressing unit allowed us to confirm valve detection and addressing, but diagnostic were limited.
• We isolated the 8 valves to separate AS-i master, and the process operated with no further faults.
• We suspect a voltage shortage issue, as the site overlooked that the valves used were high  current consumption type.
• Since the existing AS-i network still has available addresses, we recommend using the black auxiliary power cable for external supply to ensure stable operation.

FOOD INDUSTRY

Following the successful implementation of the IFM Online Real-Time Vibration Monitoring System on the HBT Burner machine last year, the customer has once again chosen IFM for another critical application – this time for the CRES machine. Their decision was driven by the proven reliability, accuracy, and importance of the system in ensuring early detection of potential mechanical issues, minimizing unplanned downtime, and enhancing overall maintenance efficiency.

FOOD INDUSTRY

Because of the flexibility of the IFM Thermal Flow sensor SA**** and the positive impression it made during the actual demo, the customer decided to install the sensor on the Winnower Pneumatic Transport, which carries not only air but also tobacco flakes, for both the CRES and HBT Burner machines.

 POWER INDUSTRY

Since 2017, this customer has been utilizing the IFM Online Vibration Monitoring System. Over the years, they have seen it’s clear value in terms of cost savings and operational effectiveness. The system has played a vital role in strengthening their preventive maintenance program by enabling early fault detection, reducing unplanned downtime, and extending equipment life. Almost every year, they have expanded the system to cover more machines, including critical equipment such as the SS4 Hot Brain Injection Pump, further proving the reliability and effectiveness of IFM’s monitoring solutions.

POWER INDUSTRY

One of the challenges we faced was the presence of other brands conducting on-site demonstrations of their vibration monitoring systems, directly comparing their capabilities against IFM’s solution. Despite these comparisons, the customer remained satisfied with the existing IFM Online Vibration Monitoring System already integrated into their machines, citing it’s user-friendliness, proven effectiveness, and cost-efficiency as key reasons for their continued trust and expansion.

WATER INDUSTRY

The IFM Vibration Transmitter has been successfully installed on a highly critical machine at one of the region’s major water treatment plans. This machine plays a vital role in the continuous operation of the facility, which is essential to the conditioning and distribution of clean water across the region.

BEVERAGE INDUSTRY

The effectiveness of the IFM O3D camera sensor for Completeness Detection (FCI- Full Crate Inspection) has been proven through it’s successful implementation in other bottling plants, which served as string references. Using this experience, we successfully replicated the FCI solution in this bottling plant, where the customer was highly satisfied with the results and is now planning to roll out the same solution across their remaining five lines.

The main challenge we encountered was during the actual demo stage, where we left the demo unit installed on their machine for about a month. At the same time, major competitors such as Sick AMG and Keyence were also conducting their own demonstrations. Despite this, our proven track record of successful applications in other plants became our advantage – ultimately leading the project being awarded to us.

PROJECT IMPACT AND BENEFITS

Given the successful application of the IFM Safety Light Curtain at the customer’s Manila Plant back years back – where they express strong satisfaction not only with the performance and reliability of the IFM sensors but also with the technical support and after-sales service provided – we have once again achieved another successful implementation of the same safety solution, this time for four palletizers at their Mindanao Plant.

BREWERY INDUSTRY

In the first quarter of the year, we introduced the IFM O3D*** 3D camera sensor to the customer and conducted a live demo to showcase it’s advanced technology as a replacement for their conventional photoelectric sensor in bottle completeness detection. Our hard work paid off – in May this year (2025) , the project was implemented and successfully commissioned within the same month.

PROJECT IMPACTS AND BENEFITS 

Improved Automation and Accuracy

• • Replaced manual-dependent inspection with a fully automated 3D vision system.
  • Consistent and precise detection of bottles regardless of size, shape, or transparency.

Reduced Manual Errors and  Material Losses

• • Eliminated human error associated with sensor repositioning during Product changeovers.
  • Reduced product rejection due to false detections or missed inspections.

Enhanced Visibility Through 3D Sensor Feedback

• • Real-time 3D imaging provides accurate depth data and object profiles.
  • Operators can view actual sensor images and detection status for verification.

Preparedness for Future Smart factory Integration

• • Ready for integration into Industry 4.0 environments.
  • Supports Ethernet for seamless communication with SCADA, PLC.