Case study

Alltech Boosts Efficiency and Innovation with eMaint CMMS

Customer Since: 2022 | Industry: Food & Beverage

Food & Beverage

Customer since 2022 3 min read

Alltech, a global leader in the agricultural sector, continuously seeks innovative solutions to enhance its operations. However, managing a vast and diverse array of assets — from manufacturing facilities to farms to distilleries — presents significant challenges. That’s why Alltech turned to eMaint computerized maintenance management system (CMMS). Now, Alltech plans to standardize even more of their global maintenance program with the power of eMaint.

Summary

With eMaint, Alltech revolutionized its maintenance processes, leading to better efficiency, reduced downtime, and a boost in operational capabilities.

Improved efficiency: Streamlined processes helped reduce downtime and increase the productivity of maintenance teams.
Sustainability gains: A significant reduction in paper waste positively contributed to Alltech’s sustainability targets.
Strategic asset management: eMaint facilitated a shift from reactive to proactive maintenance, ensuring better asset longevity and performance.

BACKGROUND

Alltech, headquartered in Nicholasville, Kentucky, has long been at the forefront of innovation in agriculture. The company’s operations span various sectors, including animal health, crop science, and even brewery distillation. In all their operations, Alltech is dedicated to fostering sustainable and efficient practices.

However, maintenance and management of such a diverse array of operations posed considerable hurdles for Alltech.

THE CHALLENGE

Prior to the integration of eMaint CMMS, Alltech relied on outdated, paper-based methods and disjointed systems that hindered its maintenance operations. The previous system lacked defined workflows and required labor-intensive methods to extract necessary data, which was both time-consuming and prone to error.

“It was a disaster,” said Robert Stuart, Alltech’s maintenance and facilities manager. “It was a mess.”

Recognizing the need for a robust solution, Alltech turned to eMaint CMMS.

IMPLEMENTATION

Alltech’s transition to eMaint CMMS marked a turning point for the company. With the introduction of eMaint’s powerful and customizable features, Alltech greatly streamlined its asset management and maintenance processes.

Since implementing eMaint, Stuart and his team have already mapped out more than 2,700 assets at the company’s headquarters, built asset registries, written defined workflows, set up part identification codes, and much more.

RESULTS

Global expansion plans and maintenance standardization across multiple sites: One of eMaint’s standout benefits for Alltech is its ability to help them standardize maintenance practices globally. “Our goal was to standardize our maintenance practices using eMaint. At different sites, you have people that have similar machines, and then they have machines that are just completely unique,“ Stuart said. “And so how do you standardize that? Well, you have to have a basic framework to operate within, and that’s what we’ve been able to achieve.” Alltech plans to expand eMaint across even more work sites, standardizing their strategy to ensure their maintenance and reliability success is scaled across the globe.

Streamlined workflows and asset management: With eMaint, Alltech finally automated and refined its maintenance workflows. Mapping out thousands of assets at Alltech’s headquarters helped establish a structured asset registry. This system facilitated quicker maintenance response times and improved the precision of the maintenance work.

Enhanced data utilization and strategic planning: With eMaint, Alltech standardized its maintenance practices across multiple locations globally. This standardization has been critical in maintaining consistency and quality. Stuart also looks forward to utilizing eMaint’s ability to effortlessly gather and analyze data on key performance indicators (KPIs) in the future, setting the stage for more informed decision-making.

Improved environmental sustainability: Moving to an electronic system, Alltech significantly reduced its paper consumption, aligning with its sustainability goals. “We say we’re good stewards,” Stuart said. “But we were killing trees to really have useless stuff just sitting there.”

Deployed mobile app to improve efficiency: Mobile integration and the ability to scan QR codes allowed field technicians to access and input data on-site, significantly speeding up the repair and documentation process. “The mobile app has been a game changer because it’s pushing information to the front line where it needs to be. But it’s also collecting all that information and bringing it back to eMaint,” Stuart said. “We can start using it to make better decisions. And we tie that back into improving our overall maintenance and reliability programs…”

Alltech Biotechnology’s integration of eMaint CMMS has transformed how the company manages and maintains its numerous and varied assets. By using eMaint to switch from a fragmented, inefficient process to a streamlined, effective management system, Alltech overcame operational challenges and set itself up for further innovation and improved sustainability in the future.

“My favorite thing about eMaint is the customization of the software. It fits for us. So, when you have a need, there’s already a solution. It’s not so much that it’s canned. You can be creative, and it’s easier to get things done.”

– Robert Stuart, Maintenance and Facilities Manager at Alltech

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