English Deutsch Italiano
EagleBurgmann Logo
myEagleBurgmann Logo

Making Hidden Issues Visible:
How GLACONCHEMIE Prevented Failures with Smart Condition Monitoring

Case Study

GLACONCHEMIE GmbH, based in Merseburg, Germany, specializes in the sustainable processing of by-products from biodiesel production. The company produces high-purity pharmaceutical and technical glycerin, as well as innovative derivatives for industries such as pharmaceuticals, chemicals, cosmetics, and food.

By consistently using renewable plant-based raw materials, resource-efficient processes, and continuous R&D, GLACONCHEMIE stands for sustainable and future-oriented chemical production.

 

Initial Situation:

Mechanical irregularities caused repeated damage to a thin-film evaporator during operation — despite an established solution (API Plan 53 with an additional forced circulation system)

The consequences:

  • Repair costs of €20,000–25,000 per incident
  • Multiple failures within a short period
  • Unclear root cause, with only indications of mechanical issues

Challenge:

Recurring failures without a clear root cause led to high costs and operational risks.

IMG_4359.JPG

Solution:

EagleBurgmann implemented its Smart Condition Monitoring Service to enable realtime visibility of cricital operating parameters.

The solution included:

  • Temperature monitoring in supply and return lines
  • Visualization of system behavior
  • Additional diagnostics (e.g., ultrasonic flow analysis)
  • Expert-based analysis of sensor data
IMG_4356.JPG

Objective:

Early detection of anomalies and prevention of further seal failures.

Implementation and Insights:

Immediately after commissioning, the monitoring system revealed a critical issue:

  • Identical temperature readings in supply and return lines
  • Physically implausible behavior

Immediate insight:

The cooling system was not functioning properly.

Further analysis identified:

  • A clogged heat exchanger
  • Root cause: deposits in a semi-open cooling water circuit

Key moment:

The issue was identified immediately after the monitoring started – before another failure occured.

2026-05-26_13-30-33.jpg
2026-05-26_13-31-51.jpg

Results / Value:

With Smart Condition Monitoring, GLACONCHEMIE was able to:

  • Prevent another mechanical seal failure
  • Identify the true root cause (cooling issue)
  • Avoid a potential plant shutdown
  • Gain full transparency into real system behavior

Additional benefits:

  • Without monitoring, the issue would only have been detected after another failure
  • Reduced risk for other equipment (e.g., decanter systems)

Key Benefits at a Glance:

  • Early detection instead of reactive maintenance
  • Full transparency instead of operational blind spots
  • Reduced unplanned downtime
  • Measurable ROI through avoided failures

 

Core Message:

Smart Condition Monitoring makes hidden issues visible – and prevents failures before they happen.

 

Want to benefit from the advantages of the Smart Condition Monitoring System?

Contact us