Machine condition monitoring system

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Overview
Plant Essential is a digital service designed to improve plant efficiency through comprehensive analytics, real-time monitoring and detailed reporting. It provides a suite of Bühler Insights dashboards for fast analysis of plant performance and supports continuous improvement.

Key benefits

• Continuous improvement: enables fast analysis of events to improve plant availability (event monitoring, critical error monitoring, event tables).
• Data-driven decision making: real-time monitoring and analytics for transparency and predictive actions.
• Operational efficiency including OEE: stabilises production, reduces operating and energy costs and helps identify major losses and root causes.

Key features

• Suite of Bühler Insights dashboards providing an overview of plant performance.
• Event analysis: section-based event monitoring, flexible event tables and easy export to Excel.
• Scale accuracy analysis: detection of overdosing, including micro ingredients, to improve dosing accuracy.
• OEE tracking and continuous improvement: measurement, tracking and support for improving overall equipment effectiveness.
• Real-time KPI monitoring (moisture, protein, fat, temperatures) and IoT integration for automated parameter adjustments.
• Algorithms that continuously update production parameters to optimise efficiency.

Key topics
Plant Essential supports digitalisation, resource efficiency and process stability by providing analytics and monitoring tools that help operators stabilise processes, increase throughput and reduce waste.

Application possibilities

• Premix and concentrates
• Aqua feed
• Pet food
• Animal feed and other feed mill processes requiring monitoring, dosing accuracy and OEE tracking

Downloads
Flyers and technical documents for Plant Essential and the Companion Plus app are available for download (PDF).

Technical specifications

• Product type: Digital service / SaaS for plant performance analytics (Bühler Insights).
• Components: dashboards, event tables, KPI trackers, OEE modules.
• Functions: real-time monitoring, event monitoring, critical error monitoring, scale-accuracy analysis, Excel export.
• Integration: IoT data ingestion and integration with machine control systems for automatic adjustments.
• Primary goals: improve plant availability, stabilise production, reduce operating and energy costs, detect dosing inaccuracies.