Smart sensors take maintenance to a new level at Cromogenia's factory

Successful maintenance is based on preventing problems before they affect production. This is the philosophy that guides us at Quant, and now it is being implemented at Cromogenia’s factory in Barcelona. We have taken a significant step towards predictive, data-driven maintenance by installing Schaeffler’s intelligent vibration sensors on production-critical equipment.

“As part of our collaboration with Cromogenia in late 2024, we saw an opportunity to develop the plant’s maintenance practices. Our customer previously performed vibration measurements manually once a quarter, so continuous and intelligent measurement was a natural next step. Now we are moving step by step towards a modern, data-driven solution,” says Andreas Ekstrand Larsson, Operational Excellence Engineer, Quant.

The sensors were installed on motors, pumps and fans, among other things, based on their production importance. The system is currently learning how the devices work and continuously collecting data on the condition of the machines.

“Already, the sensors have identified anomalies that have attracted attention in maintenance. The system automatically sends email alerts and indicates the most likely cause, which speeds up and clarifies the response,” says Igor Marzolla, Operational Excellence Engineer, Quant Spain.

quantPredict brings intelligence and predictability to maintenance
During the installation, we faced some practical challenges, such as ensuring optimal mounting surfaces for the sensors and maintaining a reliable connection.

“One sensor was initially out of range, but Schaeffler's new generation gateway devices offered a better range and a solution was quickly found,” says Larsson.

At the heart of the solution is quantPredict, a predictive maintenance platform developed by Quant. It combines data generated by sensors and utilizes artificial intelligence and machine learning to identify trends, predict failures, and guide actions.

“quantPredict transforms raw data into clear, concrete action recommendations. For our customers, it brings significant improvements in plant reliability,” says Larsson.

The project is just beginning. During May, 10 more new sensors were installed at two adjacent factories. This way, we are building an even more comprehensive package that strengthens production continuity and takes maintenance forward in the long term.

More sustainable, efficient and plannable production
Predictive maintenance also supports sustainability. When problems are detected early, repairs can be planned around production schedules. This reduces waste, prevents environmental pollution, and extends the life of equipment.

“When we can anticipate equipment failure, we can prepare and coordinate work with production. It brings savings to the customer and a more predictable workday for us,” says Marzolla.

We believe that as the system develops, the value it provides will become more concrete.

“The collaboration has started well, and we are very interested in the possibilities of the new technology. It has been interesting to see how real-time data brings more transparency into the condition of the machines and helps us plan maintenance better. We are looking forward to seeing what the system will bring as we get more data,” says Maintenance & Investment Director, Joan Carles Massachs, Cromogenia Spain.

This project is a strong example of how digital tools, expertise and customer collaboration can transform maintenance from reactive to proactive, while creating real added value for production.