Case Study: a largest single-site malting facility achieves zero VFD downtime with LSI

Largest Single-Site Malting Facility Company - Customer Case Study

The largest single-site malting facility in the United States faced persistent and increasing variable frequency drive (VFD) failures on its germination decks, causing costly unplanned downtime. The facility turned to LSI - Logical Systems Inc to investigate the root cause and develop a solution for their critical 24/7 operation.

LSI diagnosed the issue as an outdated control scheme incompatible with mechanical wear and replaced the legacy VFDs with Rockwell Automation PowerFlex 755 models. They implemented a new "Droop Follower" speed control scheme for robust load sharing. The solution, which included design, fabrication, and installation, eliminated all VFD-failure-related downtime since its installation in May 2020, optimized system performance, and improved maintainability for the customer.