For Schempp, a 140-hectare biogas producer in Europe, operational efficiency is the lifeblood of the business. By integrating Tan Delta’s advanced sensor technology, the team successfully transformed their maintenance strategy—moving from rigid, time-based oil changes to smarter, condition-based maintenance. The results have been transformative: substantial cost savings, reduced downtime, and unexpected insights that are optimizing their entire production process.
Organizational Overview
Industry: Agriculture/Energy
Size: Medium-scale farm (140 hectares)
Key Operations: Crop cultivation (corn, sugar beet, grain), livestock farming, whole crop silage, biogas plant with two gas engines.
The Challenge
Operating two high-performance gas engines, Schempp faced the inefficiencies of traditional, time-based maintenance schedules. The goal was simple but critical: reduce the frequency of oil changes without compromising engine health, performance, or longevity.
The Solution: Real Time Intelligence
By embedding Tan Delta sensor technology directly into their gas engines, Schempp gained the ability to monitor oil condition in real-time. This technological upgrade empowered the team to move beyond OEM-recommended intervals.
Instant Efficiency Gains
Oil change intervals were successfully extended from the standard 400 hours to an initial 800 hours, with a clear roadmap toward 1,000 hours.
Validation
Rigorous, parallel lab testing confirmed that the sensor data was both accurate and reliable, giving the team the confidence to trust real-time insights over outdated manual schedules.
The Impact: Financial & Operational ROI
The adoption of Tan Delta technology translated immediately into tangible business value:
Substantial Cost Savings
Schempp realized a significant reduction in operational costs, saving EUR 2,772 per engine annually.
Operational Optimization
The system did more than just track oil health—it provided a valuable two-day "early warning" lead time for issues involving feed mixtures, directly impacting the consistency of their biogas output.
Conclusion
Schempp’s integration of Tan Delta sensors is a textbook example of how precision monitoring drives both sustainability and profitability. By gaining deeper visibility into engine health, Schempp has not only lowered maintenance costs but has also optimized their wider production processes. As the company continues to refine its condition-based maintenance strategy, it remains at the forefront of agricultural innovation, proving that smarter data leads to smarter business.