GEA launches digital monitoring tool to boost reliability in dairy and beverage plants

GERMANY – GEA has introduced a new digital condition monitoring solution for the dairy and beverage sector.

The tool, known as GEA InsightPartner® EvoHDry, allows operators to track machine performance in real time and prevent unplanned shutdowns.

The system applies predictive analytics to detect early warning signs of equipment degradation.

By monitoring parameters such as temperature, pressure, vibration, and flow, operators receive instant updates on machine health through both an app and web platform.

One of the most common causes of downtime in dairy plants is the loss of suction pressure in vacuum pumps within evaporation systems.

This reduces efficiency, lowers output, and can force sudden shutdowns. According to GEA, the EvoHDry tool identifies these problems early and alerts teams before failures occur.

Angela Yeung, Digital Portfolio and Strategy Lead for Liquid & Powder Technologies at GEA, said the solution gives processors more control over operations. “Unplanned downtime remains the biggest challenge for dairy processors. By using predictive insights, customers can intervene before failures occur, reducing costs and improving efficiency. With GEA InsightPartner® EvoHDry, operators gain clear insight into machine health. Instead of reacting to unexpected shutdowns, they can plan maintenance based on reliable diagnostics – keeping production stable and output consistent.”

Many plants still struggle with alarm overload in their SCADA systems. Operators often face hundreds of notifications each day, making it difficult to separate urgent issues from routine alerts. Skilled technicians are also in short supply, and manual checks consume valuable time.

GEA designed EvoHDry to reduce these pressures by combining data-driven guidance with expert recommendations.

This helps operators focus on the most critical issues, streamline maintenance schedules, and maintain consistent production.

Built with accuracy and security

The setup includes sensors for vibration, flow, and pressure, supported by an edge gateway that processes data locally before sending it to the GEA Cloud.

By working independently of plant IT networks, the system strengthens security and ensures rapid response times. GEA specialists then validate diagnostics, combining human expertise with automated analysis.

The monitoring tool reflects GEA’s long experience as an equipment manufacturer. It has been designed for evaporators, spray dryers, pumps, and rotating equipment, covering processes from vacuum stages through to CIP cycles.

By aligning predictive recommendations with maintenance schedules, operators can extend equipment lifespan, reduce costs, and stabilize long-term performance.

EvoHDry also forms part of the GEA Service Performance Partnership, which integrates digital tools with on-site service support.

Through this model, GEA aims to help processors improve reliability, productivity, and sustainability across their operations.

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