The ESA app comprises modules for performance monitoring, maintenance management, anomaly detection, logbook functions and document storage. At Interzero, maintenance management is a central component of the system. As one of the largest operators of plastics sorting facilities in Europe, the company manages extensive plant technology that requires structured planning, coordination and documentation of maintenance activities.
By introducing the digital maintenance module, Interzero has centralised its maintenance processes. The application provides a detailed status overview of machines and enables the management of work orders via desktop and mobile devices. Maintenance activities can be documented directly at the equipment, including image capture. For each machine, step-by-step instructions are stored in multiple languages, supporting standardised procedures and reducing the risk of errors.
According to the company, the digital documentation and structured workflows have reduced administrative effort and improved system availability. Maintenance intervals are currently defined on the basis of operational experience. In the next phase, Interzero plans to integrate automatically collected machine data and digitally documented maintenance histories to establish data-based maintenance intervals. The objective is to further increase plant availability and reduce unplanned downtime.
Interzero is also involved in the ongoing development of the ESA app as a pilot customer. In its pilot plants, all modules of the software are in use, including performance monitoring, anomaly detection, logbook and document storage. The collaboration builds on previous projects in which Eggersmann implemented sorting plants as a general contractor. Through its involvement in software development, Interzero contributes operational requirements to the further refinement of digital plant management tools for plastics recycling.
