The MyUNTHA maintenance manager improves the efficiency of shredders through intelligent sensor technology and precise maintenance planning. It reduces downtimes and lowers operating costs in the long term.
The challenge: Efficient maintenance during intensive operation
UNTHA shredding technology offers industrial shredding machines that can be used both stationary and semi-mobile. The principle is simple: The machines shred the input material using mechanical processes. Slow-running rotors with various cutting systems are used in the process. The operator can select the desired input material in the configuration. The required throughput can be adjusted during operation.
These shredders are used in many industries to prepare raw materials or waste for further processing. In the recycling industry, they shred materials such as plastics, metals, glass, or wood to make them easier to recycle. Energy-intensive industries like the cement industry rely on shredding non-recyclable waste such as tires and rubber to use as alternative fuel for energy production.
Due to their function, shredding machines are extremely robust. However, they are still subject to significant wear, especially when processing metallic waste. To ensure reliable machine operation, it is important to replace worn or defective components in a timely manner. Traditionally, this requires regular on-site maintenance. However, the individual components do not wear out evenly, which means maintenance intervals are scheduled cautiously and as frequently as possible. This presents significant potential for optimization.
The Solution: Smart Technologies for Maintenance Management
In recent years, UNTHA has developed its shredders into smart products. They are now equipped with additional sensors and internal computing power. This has enabled UNTHA to digitize its machines and expand its business model with additional digital services. Thanks to the sensor data, the root cause of a problem can often be identified remotely, allowing targeted support in finding a solution.
Connectivity and the MyUNTHA Portal
At the heart of UNTHA’s smart services is the customer portal “MyUNTHA.” Every buyer of a new machine receives access and can use several free services. The large XR and ZR series machines come factory-equipped with a cloud connection. For smaller machines, such as those in the RS series, connectivity is optional and available as an add-on package.
The connection is established via mobile network and is based on the IoT platform Cumulocity. In MyUNTHA, the data is further processed and presented in a form that is useful to the customer. To save bandwidth and reduce connection costs, each machine is also equipped with an industrial PC that functions as an edge device. It collects and processes the data locally first, before sending only the refined data to the cloud. This enables analysis and alerts even without a constant cloud connection, thereby increasing process reliability.
The Assistance System UNTHA GENIUS
The MyUNTHA customer portal allows users to view statistics, trends, and analyses and respond immediately to any deviations. Thanks to long-term storage of process data, important trends can be analyzed to sustainably improve the efficiency of the machines.
In addition, UNTHA GENIUS enables immediate correction of deviations. Thresholds are continuously monitored, and process-critical components are constantly checked. If deviations from the plan or disruptions occur, users receive instant status notifications via email or SMS. This allows for rapid response and quick stabilization of the production process.
UNTHA GENIUS also offers features to ensure the security of stored data. The edge device is equipped with an integrated firewall to protect against cyberattacks. An encrypted end-to-end connection to the cloud is provided, and the platform is hosted in Germany, ensuring maximum data protection. Access to the customer portal requires user authentication, ensuring that only authorized individuals can log in.
The MyUNTHA Maintenance Manager
The MyUNTHA Maintenance Manager is an innovative solution for the predictive planning of maintenance tasks, accessible via tablet or PC. The integrated assistance system UNTHA GENIUS monitors the condition of maintenance-intensive machine components and determines the optimal maintenance time.
The Maintenance Manager displays all machines within the company and all pending maintenance tasks. It provides detailed information about each machine along with precise maintenance instructions. These guide technicians step by step through the maintenance process, ensuring that no tasks are forgotten or performed incorrectly.
Based on the machine’s previous maintenance history, the system also suggests the ideal time for the next service. This ensures that required maintenance is planned and carried out on time. The result is consistently high machine performance and a significant reduction in unplanned downtime.
The Maintenance Manager thus plays a central role in managing a company’s machine fleet. Operating costs are reduced in the long term, and downtime is minimized. The system also offers numerous additional benefits, including precise maintenance scheduling, improved productivity, comprehensive and clear documentation, and direct notifications about upcoming tasks.
The Result: Increased Efficiency and Reduced Operating Costs
The UNTHA GENIUS assistance system helps companies operate their machines more efficiently. Continuous monitoring reduces unplanned downtimes, and problems are detected and resolved early. This leads to increased machine availability and overall production performance. The Maintenance Manager supports the planning and execution of maintenance tasks, ensuring they are carried out regularly and on time. This extends machine lifespan and reduces both downtime and operating costs.
