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Deploying IMI TWTG NEON non-Ex sensors in food and beverage manufacturing
Written By Stephen Howes
November 5, 2026
Improving equipment reliability while protecting production and product quality.
Food and beverage manufacturers face constant pressure to maintain production, protect product quality and use energy and resources efficiently. Pumps, motors, conveyors, mixers, refrigeration systems and supporting utilities often operate across multiple shifts and demanding production schedules. When critical equipment fails unexpectedly, the consequences can include lost production, wasted product, higher maintenance costs and, depending on the application, risks to product quality or food safety.
Traditional maintenance programmes remain essential, but scheduled inspections may not reveal how equipment condition changes between visits. Wireless condition monitoring gives maintenance teams an additional source of information. It can help them identify changes in equipment behaviour, investigate potential faults and plan interventions before problems develop into more serious failures.
IMI TWTG NEON non-Ex sensors offer a practical way to introduce additional monitoring points in suitable food and beverage manufacturing environments, without necessarily installing new signal cabling or external power supplies. Using low-power LoRaWAN connectivity, the sensors can transmit measurements from selected assets to a monitoring application, supporting more informed maintenance decisions.
Food and beverage facilities present particular installation challenges. Cleaning regimes, moisture, chemical exposure, hygienic design requirements, production processes and hazardous-area classifications must all be considered. A successful deployment therefore starts with a clearly defined maintenance objective and a thorough assessment of both the equipment and its operating environment.
1. Identify the assets that matter most
The first step is to identify where additional condition information could deliver the greatest operational benefit, rather than attempting to monitor every asset across the facility.
A failure affecting a critical production pump, conveyor drive or refrigeration component can disrupt an entire production line. Problems with steam, compressed air, cooling water or other supporting utilities may affect several processes at the same time.
Engineering and maintenance teams should consider:
Production impact: How would equipment failure affect throughput, production schedules, product quality or food safety?
Failure history: Which assets experience recurring breakdowns, overheating, bearing deterioration or other maintenance problems?
Standby capacity: Can production continue if the asset fails, or does it represent a single point of failure?
Inspection requirements: Which assets require frequent manual checks or are difficult to access safely?
Maintenance costs: What are the costs associated with emergency repairs, replacement parts, downtime and wasted production?
Energy and utility performance: Could deteriorating equipment increase the use of electricity, steam, compressed air, water or refrigeration capacity?
Existing monitoring: Do current control and monitoring systems provide sufficient information about the asset’s condition?
Potential candidates include:
Pumps used for water, ingredients and other process fluids, where the installation is suitable.
Electric motors, conveyor drives and gearboxes.
Mixers, agitators and other rotating production equipment.
Fans, extraction equipment and ventilation systems.
Refrigeration and cooling-system auxiliaries.
Compressed-air and hydraulic utility equipment.
Steam traps and selected steam-system components.
Pumps and motors supporting cleaning-in-place systems.
The appropriate assets will depend on the production process, the consequences of failure and the information needed. Existing programmable logic controllers, supervisory control and data acquisition systems, and other instrumentation may already provide sufficient data for some applications.
Wireless asset health monitoring is particularly valuable where it addresses an identified information gap. A focused pilot involving a small number of critical assets can test the approach, reveal installation constraints and demonstrate whether the additional data leads to better maintenance decisions.
2. Select the appropriate NEON sensor
Different measurements provide insight into different aspects of equipment condition. Sensor selection should begin with the problem that needs to be investigated, followed by the required measurement range and the intended use of the data.
Vibration monitoring for pumps, motors and production equipment
Rotating machinery is often a logical starting point for condition monitoring in food and beverage manufacturing. Motors, pumps, mixers, fans and conveyor drives can develop mechanical problems that affect their vibration behaviour before a breakdown occurs.
Changes in vibration may indicate potential issues such as:
Bearing deterioration or lubrication-related problems.
Shaft misalignment.
Mechanical looseness.
Rotor imbalance.
Gearbox or coupling problems.
The IMI TWTG NEON Vibration Sensor (Non-Ex) provides three-axis vibration measurements and spectral analysis across a published frequency range of 0.5 Hz to 6.66 kHz. Its onboard processing and configurable algorithms support the identification of significant changes in vibration behaviour, with scheduled and event-driven data transmission.
For example, monitoring a motor that drives a conveyor or process pump can help establish its normal vibration characteristics. Maintenance teams can then review later measurements for changes that may warrant closer inspection, helping them prioritise planned work before an issue contributes to unplanned downtime.
Installation position and mounting quality are important. The sensor must be mounted in accordance with the manufacturer’s instructions and in a location that provides representative measurements. Operating speed, load and normal variations in production duty should also be considered when interpreting the data.
Temperature monitoring for motors, bearings and utilities
Temperature provides complementary information about equipment condition. Abnormal thermal changes may be associated with bearing deterioration, inadequate lubrication, excessive loading, mechanical friction or cooling-system problems.
The IMI TWTG NEON Temperature Transmitter (Non-Ex) accepts compatible thermocouple or resistance temperature detector inputs. This provides an option for monitoring selected measurement points on suitable production and utility equipment.
Potential applications include:
Motor and bearing housings.
Gearboxes and other mechanical drive systems.
Selected refrigeration and cooling-system components.
Utility equipment where temperature changes may indicate deteriorating performance.
Suitable steam-system applications, subject to the specifications of the transmitter and selected probe.
For example, monitoring a motor bearing housing may help identify an abnormal temperature trend between routine inspections. When reviewed alongside vibration data, equipment history and operating conditions, this information can help maintenance teams decide whether further investigation is necessary.
Temperature transmitter with external stainless steel probe for industrial temperature monitoring.
The probe type, measurement range, attachment method and installation point must match the application. The transmitter and probe must also be suitable for the expected operating conditions, hygiene requirements and cleaning arrangements.
Pressure monitoring for process and utility systems
Pressure monitoring can provide additional visibility of selected fluid-handling and utility systems. Potential applications include suitable water circuits, hydraulic power units and other process or service systems where a change in pressure provides useful information about equipment or system performance.
The IMI TWTG NEON Pressure Sensor (Non-Ex) provides wireless pressure monitoring for applications where its measurement range, accuracy, process connection and installation arrangement meet the site’s requirements.
For example, monitoring a suitable utility circuit may help identify pressure readings that depart from an established operating range. Such changes can indicate a potential leak, restriction, equipment malfunction or variation in operating conditions, although the pressure reading alone does not establish the cause.
Pressure monitoring should complement, rather than replace, instruments and protective systems required for process control, product quality or safety.
Steam-trap monitoring and energy efficiency
Steam is used in many food and beverage processes, including heating, cooking, pasteurisation and cleaning. Steam traps discharge condensate while limiting the loss of live steam. When a trap becomes blocked or leaks, it can contribute to inefficient operation, avoidable steam losses, higher operating costs and additional maintenance requirements.
The IMI TWTG NEON Sonic for Steam Trap Monitoring (Non-Ex) combines acoustic and temperature sensing to assess steam-trap condition. Its published capabilities include onboard diagnostics designed to identify potentially blocked or leaking traps.
In suitable non-hazardous locations, the sensor can provide maintenance teams with additional information about steam distribution and associated utilities. It may help them prioritise inspections and investigate potential problems between scheduled maintenance rounds.
The sensor’s operating limits, mounting requirements, process-temperature range and environmental suitability must be checked against the specific installation. Steam systems may also include locations requiring hazardous-area certification, which must be assessed separately.
3. Assess hygiene, cleaning and environmental conditions
Food and beverage manufacturing environments vary considerably. A dry packaging hall, wet processing area and steam utility room present very different installation challenges. Sensor suitability must therefore be assessed at the proposed measurement point.
Cleaning and washdown
Production areas may be cleaned using water, detergents, disinfectants or other chemicals. Some locations may also be exposed to high-pressure washdown or temperature-controlled cleaning procedures.
Before installation, establish:
The frequency and method of cleaning.
The chemicals used and their potential effects on the device and mounting materials.
The expected exposure to water, condensation and washdown.
Whether the published ingress-protection rating is suitable for the actual environment.
Whether the device could be exposed to direct impact or damage during cleaning.
An ingress-protection rating does not, on its own, establish suitability for every cleaning method or chemical exposure. Check the device’s technical documentation against the site’s actual conditions.
Hygiene and contamination control
Sensor location is particularly important in facilities with strict hygiene requirements.
A device suitable for monitoring a motor in a dry utility room may not be suitable for a wet production area or a location subject to stringent hygienic-design requirements. Materials, mounting arrangements, crevices, cleaning access and the potential for contamination must all be assessed.
Do not assume that a non-Ex sensor is hygienically designed, suitable for food contact or approved for a particular cleaning-in-place or washdown regime. These requirements must be verified for the product and application.
Where a sensor would be installed near exposed ingredients, product-contact equipment or another hygiene-critical area, involve the site’s engineering, food safety and quality teams before selecting the location. Where appropriate, placing the sensor outside the product zone may provide useful condition information while reducing the risk of interfering with hygiene controls.
Temperature, humidity and mechanical exposure
Check ambient temperature, condensation, moisture, dust, vibration and potential impact. Confirm that the device, any external probe or connection, and the mounting arrangement are suitable for the expected conditions.
Sensor placement should also account for routine maintenance, equipment guarding, operator access and the risk of damage during production or cleaning.
Hazardous-area classification
Some food and beverage processes may create potentially explosive atmospheres. Examples include certain applications involving combustible dust from flour, grain or sugar, as well as processes involving flammable vapours or gases.
NEON non-Ex variants are intended for environments where the relevant hazardous-area certification is not required. Before installation, a competent site assessment must establish whether the location requires ATEX, IECEx or another applicable hazardous-area approval.
A non-Ex sensor must not be installed in a location requiring certification that it does not hold. Where certification is required, select an appropriately approved alternative.
4. Plan LoRaWAN connectivity and data integration
NEON sensors use LoRaWAN, a low-power wireless networking technology designed for long-range data transmission. Battery-powered operation can reduce the need for new signal cabling and external power supplies, making it easier to introduce additional monitoring points on suitable existing assets.
This can be useful in food and beverage facilities where machinery is distributed across production halls, packaging areas and utility rooms, or where installing additional cabling would be disruptive.
However, wireless performance must be verified under representative site conditions. Metal equipment, building structures, enclosed machinery and gateway positioning can all affect radio coverage.
Before installation, confirm:
LoRaWAN coverage at each proposed sensor location.
Gateway placement and network availability.
The correct regional frequency configuration.
The route by which data will reach the monitoring application.
How the measurements will be displayed, reviewed and retained.
How alerts will be communicated to maintenance personnel.
Who will manage the devices, gateways and access permissions.
The data architecture should be agreed before commissioning. Depending on the application, monitoring information may be viewed through the IMI TWTG SolidRed platform or integrated with another compatible industrial Internet of Things or data system. The device configuration, data decoder and integration method must be verified for the selected application.
Cybersecurity and network access should be considered from the outset. Involve the site’s automation and information technology and operational technology teams to establish how devices and gateways will be managed, who can access the information, and how the monitoring solution will connect to existing systems.
Where monitoring is intended to provide supplementary maintenance information, its role should remain distinct from control systems and instruments responsible for maintaining product quality or safe process operation.
5. Install and commission the sensors
A documented installation and commissioning process helps ensure that the monitoring system provides useful measurements and fits into existing maintenance, quality and production procedures.
Step 1: Confirm the asset and measurement point
Record the asset identifier, location, operating duty and reason for monitoring it. Verify that the selected position provides a representative measurement and is suitable for the device.
Step 2: Verify environmental and hygiene requirements
Confirm that the mounting method, materials and location are appropriate for the environment. Check cleaning access, washdown exposure and any hygienic-design or contamination-control requirements.
Step 3: Install according to the manufacturer’s guidance
Follow the relevant product manual and mounting instructions.
For vibration monitoring, pay particular attention to mounting position and mechanical coupling. For temperature and pressure measurements, verify the probe or sensor arrangement, connection type and permitted operating range.
For steam-trap monitoring, confirm that the installation arrangement is suitable for the trap, pipework and expected operating temperature.
Step 4: Configure communications
Configure the device and LoRaWAN connection, including the correct regional settings and network registration. Confirm that the network can receive data from the selected location and that the monitoring application can interpret the device messages correctly.
Step 5: Verify measurements and the end-to-end data path
Check that the readings are plausible for the equipment and its current operating state. Where possible, compare them with existing instruments, inspection findings or established measurements.
Confirm that the data reaches the correct asset record and that timestamps, visualisations and alerts operate as intended. Investigate unexpected differences before relying on the information for routine maintenance decisions.
Step 6: Assign responsibilities and complete the documentation
Involve maintenance, reliability, production, quality, food safety and IT/OT personnel as appropriate.
Establish:
Who reviews the measurements.
Who receives and prioritises alerts.
Who investigates potential problems.
When an issue should be escalated.
Where findings and corrective actions are recorded.
Who is responsible for maintaining the monitoring system.
Wireless technology can simplify deployment, but it does not remove the need for safe access, approved work procedures or appropriate commissioning checks.
6. Turn monitoring data into maintenance decisions
Condition monitoring creates value when the information leads to timely and appropriate action.
Once the system is operational, establish baseline measurements under representative conditions. In food and beverage production, these conditions may vary according to product type, production stage, operating speed, load, cleaning cycles and utility demand.
Review subsequent measurements against that baseline, taking account of normal variation and changes in the asset’s operating conditions.
An increase in vibration or temperature, or a pressure reading outside an agreed range, may justify further investigation. It does not necessarily prove that a component has failed or identify the underlying cause.
Maintenance teams should consider the wider evidence, including:
Current operating conditions and production schedules.
Historical measurements and known failure patterns.
Maintenance records and previous interventions.
Findings from physical inspections and other instruments.
Changes in production speed, load or product type.
The potential consequences for production, product quality, energy use and safety.
Define alert thresholds, responsibilities and escalation procedures before routine use. Establish how alerts will be prioritised, when an inspection is required and how the findings will be documented.
Where equipment condition could affect food safety, product quality or a critical process, use monitoring data within the site’s established risk-management and quality procedures. Wireless condition monitoring should not replace validated process controls, safety systems, required inspections or instruments used to maintain product quality.
7. Evaluate the pilot before expanding
A controlled pilot can help determine whether wireless condition monitoring provides useful information and can be maintained within the site’s existing engineering and operational processes.
Potential evaluation measures include:
Unplanned downtime on monitored assets.
Equipment availability and recurring failure rates.
The number and type of maintenance interventions.
Time spent on routine inspection.
Time between identifying and investigating a potential issue.
The proportion of alerts that lead to useful maintenance action.
Data availability and the effort required to maintain the system.
Installation, cleaning or hygiene constraints identified during the trial.
Examples of avoidable utility losses or inefficient operation identified through monitoring.
Record the baseline and agree the evaluation criteria before the pilot begins. Consider the number of assets being monitored, the duration of the trial and any other changes to maintenance practices or production operations during the evaluation.
A short pilot may demonstrate that the sensors and communications operate as intended, but it may not be long enough to establish a measurable reduction in infrequent failures. Interpret the results accordingly.
Once the findings have been reviewed, prioritise further installations according to asset criticality, environmental suitability and demonstrated operational value. This creates a repeatable approach to deployment, rather than assuming that every asset requires the same level of monitoring.
Practical deployment checklist
Before deploying IMI TWTG NEON non-Ex sensors in a food and beverage facility, confirm that the team has:
Identified critical assets and relevant failure modes.
Defined the purpose of each measurement and its intended maintenance outcome.
Verified sensor specifications, mounting requirements and operating limits.
Assessed cleaning, washdown, chemical exposure and hygiene requirements.
Confirmed that each proposed location is suitable for the non-Ex variant.
Verified LoRaWAN coverage, gateway requirements and data integration.
Agreed installation, commissioning and cybersecurity requirements.
Established baseline measurements, alert thresholds and response procedures.
Assigned responsibility for reviewing alerts and recording maintenance actions.
Involved quality, food safety and other relevant stakeholders where necessary.
Defined pilot evaluation criteria before considering a wider rollout.
Conclusion
Food and beverage manufacturers need reliable equipment, consistent production and effective control of hygiene, product quality and operating conditions. Wireless condition monitoring can extend visibility of selected assets, particularly where conventional monitoring is limited by access, cabling requirements or the frequency of manual inspections.
IMI TWTG NEON non-Ex sensors provide options for vibration, temperature, pressure and acoustic monitoring in suitable non-hazardous industrial environments. Their battery-powered operation and LoRaWAN connectivity offer a practical way to introduce additional measurement points without necessarily installing new signal cabling or external power supplies.
Effective deployment starts with a clearly defined maintenance problem. It also requires the right sensor, a suitable installation environment, verified wireless communications and an agreed process for responding to the data.
By combining appropriate measurements with engineering judgement and established maintenance, quality and food safety procedures, manufacturers can identify where additional condition information could support more reliable equipment, better maintenance planning and more efficient use of energy and utilities.
Stephen Howes is Product Manager, Connected Devices, at IMI.
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