After several days or weeks of inactivity, returning to production can reveal minor anomalies that went unnoticed during the shutdown: lubricant loss, leaks, corrosion, loose connections, or deteriorated components.
Starting the machinery directly at full output can turn these incidents into breakdowns, production stoppages, and even risks to workers.
For this reason, before returning to the usual pace, it is advisable to carry out a basic inspection of the most critical elements of the installation.
Even if a machine remains stopped, its components can be affected by humidity, dust, temperature changes, or pressure loss.
The most common issues include:
A preventive check makes it possible to detect these anomalies before they affect production.
Bearings are essential components in motors, pumps, gear reducers, fans, and conveying systems.
Before starting up, check that they show no corrosion, grease leakage, play, or difficulty turning. Where possible and safe, rotate the shaft manually to detect binding or abnormal noise.
The condition of the lubricant should also be checked. A change in colour, texture, or smell may indicate contamination or degradation.
Grease should not be added automatically. Both insufficient and excessive lubrication can cause overheating and reduce bearing service life.
During the first hours of operation, pay attention to possible vibrations, noise, or rapid temperature increases.
Leaks are one of the most frequent problems in pneumatic and hydraulic installations.
In compressed-air systems, the following should be checked:
A small leak can increase energy consumption, reduce actuator performance, and force the compressor to run for longer.
In hydraulic systems, check the level and condition of the fluid, as well as hoses, seals, fittings, cylinders, and filters. Cracks, deformation, or oil stains should be assessed before pressurising the circuit.
Mechanical transmissions can also undergo changes during a prolonged shutdown.
For belts, it is advisable to check tension, alignment, the presence of cracks, and possible oil contamination. A loose belt can slip, while excessive tension increases the load on the bearings.
For chains, check lubrication, corrosion, elongation, and the presence of stiff links.
Couplings, pulleys, sprockets, and their corresponding guards should also be inspected.
Any misalignment or wear detected must be corrected before operating at full load.
Before starting electric motors, verify that the ventilation grilles are clean and that there are no loose connections, moisture, or signs of overheating.
The following should also be checked:
Sensors can fail simply due to dust build-up or slight misalignment.
It is not advisable to clear an alarm without first analysing its cause. The message may provide important information about an incident prior to the shutdown.
Before starting production, the machine’s safety systems must be tested:
Once the checks have been completed, start-up should be gradual.
Whenever possible, begin with a no-load test or reduced load. Listen for any noise, monitor pressure, and observe whether vibrations, leaks, or temperature increases appear.
Then increase the load gradually until normal production conditions are reached.
Area | Check | Cleaning | No dust, moisture, or foreign objects |
|---|---|
Bearings | No noise, play, or abnormal heating |
Lubrication | Correct lubricant level and condition |
Transmission | Belts, chains, and couplings checked |
Pneumatics | No leaks and adequate pressure |
Hydraulics | Hoses, seals, and fluid level checked |
Electrical | Motors, connections, and panels inspected |
Automation | Sensors clean and no pending alarms |
Safety | Guards and emergency stops operational |
Start-up | Initial test with progressive loading |
Not necessarily. The bearing type, the lubricant used, the downtime, and the manufacturer’s recommendations should be reviewed. Over-greasing can also cause breakdowns.
Equipment that is critical for safety and production continuity, such as main motors, pumps, gear reducers, compressors, and conveyors.
Large leaks can be heard, but ultrasonic detectors can be used to locate small leaks.
It is advisable to maintain increased monitoring during the first hours and to check its parameters again at the end of the first shift.
Returning to activity after the summer should not be reduced to switching on the machines and immediately resuming production.
A simple inspection of bearings, lubrication, transmissions, pneumatic and hydraulic circuits, electrical systems, and safety elements can prevent major breakdowns.
Are you preparing to return to production? Consult ROYSE’s technical team and find the most suitable components for your installation.
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