Case Study: Baxter Healthcare

The challenge

Baxter Healthcare, a leading pharmaceutical manufacturer, needed a more proactive approach to managing asset performance across its production lines. With up to 150 critical assets per line — including pumps, motors, gearboxes, fans and conveyors — even a single unexpected failure could result in costly downtime and wasted batches. They required a solution that could give engineers early warning of degradation without disrupting their fast-moving operations.

The solution

Otoni deployed its Asset Intelligence platform across three of Baxter’s six production lines, installing over 400 Phantom VA sensors to enable live condition monitoring. The solution included:

• Real-time vibration analysis and automated alerts
• Continuous monitoring across critical rotating equipment
• Integration of AIM CMMS for asset health, maintenance and compliance
• Combined visibility of condition and maintenance data in one platform
• Streamlined scheduling of planned interventions
• Data-driven reporting to support Capex planning

This setup provided engineers with instant alerts on emerging issues — allowing them to act early, reduce risk and schedule maintenance on their terms.

Results and impact

The system has already prevented multiple asset failures and batch losses. One significant intervention involved a spray dryer exhaust fan where excessive vibration was detected — enabling engineers to act in time and protect a £1 million production batch.

Baxter Healthcare has since applied for Capex funding to expand coverage across the remaining production lines, with plans to install an additional 400 sensors.