AI-Based Condition Monitoring for Hygienic Processing

Alfa Laval has launched Clariot™, an AI-based condition monitoring solution developed for hygienic processing environments. The system provides 24/7 monitoring, diagnostics, and alerts for pumps and other rotating equipment, targeting reduced unplanned downtime and improved resource efficiency in the food and pharmaceutical industries.

Addressing Downtime in Hygienic Production
In hygienic manufacturing, unplanned equipment stoppages can result in product loss, additional cleaning cycles, water waste, production delays, and potential machine damage. Beyond direct revenue losses, downtime may affect product quality, safety, and regulatory compliance.

Clariot™ is designed to detect early signs of failure in rotating equipment, enabling operators to intervene before breakdowns occur. According to Alfa Laval, the solution builds on operational data from more than 3,000 condition monitoring units already deployed globally.

The system is intended for use in pumps and other rotating machinery such as agitators operating in wet and washdown environments typical of hygienic process lines.

System Architecture and Digital Integration
Clariot™ consists of three main components: the Clariot VX sensor, the Clariot Connect gateway, and an integrated analytics platform. Together, these elements form what the company describes as a complete digital handshake system.

The Clariot VX sensor is engineered for wet production environments and frequent process changeovers. It is pre-installed on selected Alfa Laval pumps and can be deployed on equipment from most device brands. Sensor data are transmitted to the gateway and analyzed to identify deviations related to mechanical condition, process irregularities, or equipment wear.

The solution operates as a standalone application, independent of internal business-critical IT systems. It complies with IEC 62443-3-3 Security Level 1 (SL1), addressing cybersecurity requirements for industrial automation and control systems.



From Condition Monitoring to Predictive Maintenance
Clariot™ supports predictive maintenance strategies by converting sensor data into actionable insights. Continuous monitoring of vibration and operating conditions enables early identification of bearing wear, cavitation, misalignment, or other mechanical issues.

In facilities with multiple pumps, even limited downtime events can have measurable financial impact. Alfa Laval cites an example of a plant operating 50 pumps, where one unplanned shutdown per quarter could result in annual losses of up to €80,000. The company indicates that the cost of deploying Clariot™ is less than one-tenth of this scenario, positioning the system as a preventive investment.

By issuing real-time notifications, the system enables maintenance teams to schedule inspections and repairs proactively, reducing emergency interventions and avoiding unnecessary line interruptions.

Scalability and Cross-Site Benchmarking
Clariot™ is designed as a scalable solution, enabling deployment across multiple production lines and facilities. Aggregated data can support benchmarking between factories, contributing to performance optimization across distributed manufacturing operations.

The system integrates AI-driven analytics with industrial condition monitoring to enhance uptime, reduce resource waste, and support data-based maintenance planning in hygienic production environments.