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  • Why Yellotec’s Calibration Services Are Critical for Reliable Condition Monitoring

    In today’s data-driven maintenance environment, the accuracy of your measurement equipment directly impacts your ability to detect faults early, prevent failures, and optimise asset performance. At Yellotec, calibration is more than just a service, it’s a critical component of a proactive reliability strategy.

    What Is Calibration and Why Does It Matter?

    Calibration is the process of comparing a measurement device against a known, accurate standard to detect and adjust for errors, to ensure they produce accurate, repeatable, and reliable results. Verification is the process of confirming that a product adheres to specified requirements and standards of the Manufacturer.

    In industries such as mining, manufacturing, oil and gas, and power generation, even minor measurement deviations can lead to:

    • Incorrect diagnostics
    • Missed failure warnings
    • Unplanned downtime
    • Increased maintenance costs

    Accurate instruments are the foundation of predictive maintenance and condition monitoring; two key pillars in Yellotec’s mission to help clients predict and prevent all failures. 

    Yellotec’s Calibration Services: Built for Precision and Reliability

    Yellotec offers ISO 17025 accredited calibration services in temperature, for Infrared cameras, and Fluke approved verification for Prüftechnik Alignment and Vibration equipment, ensuring that your equipment meets the highest international standards. 

    1. High-Tech Calibration Laboratory

    All calibration work is conducted in a state-of-the-art test and calibration lab, equipped to handle a wide range of condition monitoring instruments.  This includes:

    • Diagnostic testing
    • Precision measurement calibration/verification
    • Controlled calibration environments

    2. Comprehensive Inspection and Cleaning

    Calibration goes beyond simple adjustments. Yellotec performs:

    • Full system cleaning
    • Detailed inspection of all components
    • Verification that every part is functioning correctly

    This ensures your equipment is not only accurate, but also operationally reliable.

    3. Preventative Repairs and System Optimisation

    During calibration, technicians assess the system holistically. If issues are identified, basic preventative repairs are carried out to ensure the system performs optimally as a whole. For other repairs the unit is returned to the Manufacturer after consultation with the customer.

    This proactive approach helps eliminate hidden faults before they escalate into costly failures.

    4. Firmware Updates and System Enhancements

    To keep your equipment aligned with the latest technological advancements, Yellotec also updates firmware to current versions.

    Local and International Repair Capabilities

    Yellotec provides both:

    • Local (South Africa) service and calibration centre support
    • International repair services from Germany, when required

    This ensures access to specialised OEM expertise while minimising downtime through local support channels. 

    Supporting a Wide Range of Technologies

    Yellotec’s calibration services support a broad spectrum of condition monitoring technologies, including:

    • Vibration analysis
    • Infrared thermography
    • Ultrasound analysis
    • Alignment systems
    • Online monitoring systems
    • Vibration sensors

    This integrated capability allows clients to maintain consistency and accuracy across all reliability disciplines.

    Why Choose Yellotec for Calibration Services?

    1. Proven Expertise

    With decades of experience in reliability engineering, Yellotec combines technical knowledge with practical industry insight.

    2. Accredited and Certified Quality

    ISO 17025 Accredited and ISO 9001-certified laboratories ensure compliance with global calibration standards.

    3. OEM Approval

    Work is aligned with original equipment manufacturer specifications for maximum accuracy and reliability.

    4. Integrated Reliability Solutions

    Calibration is seamlessly integrated with consulting, diagnostics, and condition monitoring services.

    5. End-to-End Support

    From calibration and repair to training and field services, Yellotec provides a complete reliability ecosystem.

    Calibration is often overlooked, yet it is one of the most critical elements in any reliability programme. Without accurate data, even the most advanced condition monitoring technologies cannot deliver value.

    With its ISO-certified labs, advanced diagnostic capabilities, and proactive service approach, Yellotec ensures your equipment delivers the precision you need to make confident, data-driven decisions.

    Ready to Improve Your Measurement Accuracy?

    Partner with Yellotec for expert calibration services that enhance reliability, reduce risk, and keep your operations running at peak performance.

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  • Improving Gearbox Test Consistency with Atten[2] OilWear Sensor

    Reliable gearbox validation with accurate oil cleanliness monitoring in bubbly conditions.

    This case study shows how Hyster Yale Material Handling improved gearbox validation by solving unreliable oil cleanliness testing caused by air bubbles.

    Incotech Ltd integrated the Atten[2] OilWear S sensor into a test bench, enabling real-time monitoring and accurate separation of bubbles from contaminants.

    This resulted in faster testing, reliable measurements, simpler system design, and improved confidence in gearbox quality before assembly.

    Article Highlights:

    • Hyster Yale Material Handling faced inconsistent gearbox testing due to air bubbles affecting oil cleanliness measurements.
    • Traditional particle counters struggled in low-pressure, aerated oil conditions.
    • Incotech Ltd integrated the Atten[2] OilWear S sensor into a custom test bench.
    • Real-time monitoring enabled accurate differentiation between air bubbles and contamination particles.
    • Eliminated the need for complex high-pressure systems to suppress bubbles.
    • Reduced testing time and improved repeatability of results.
    • Increased confidence in gearbox quality before assembly.
    • Scalable solution for other applications with foamy or aerated oil systems.

    Key Takeaway:

    Atten[2] OilWear S sensor enables accurate, real-time oil cleanliness measurement even in bubbly, low-pressure conditions—helping Hyster Yale Material Handling achieve faster, more consistent, and reliable gearbox validation without complex system modifications.

  • Electrical Signature Analysis for Pump Performance

    A power plant uses electrical signature analysis for performance assessment.

    In this All Test-Pro case study, a power plant used Electrical Signature Analysis (ESA) to investigate performance issues in aging water pump motors by measuring voltage and current signals to assess both electrical and mechanical conditions of the entire system. 

    The analysis revealed that the motors themselves were functioning properly, but identified turbulence in the water flow as the root cause of poor pump performance—something other diagnostic methods had missed.

    Read the Full Article

    Article Highlights:

    • Pump performance issues identified in aging system
    • ESA used to assess full motor and pump condition
    • Motors found electrically and mechanically sound
    • Turbulence detected as root cause of poor performance
    • Issue was missed by other diagnostic methods
    • ESA enabled targeted corrective action
    • Highlights value of predictive maintenance and combined diagnostics

    Key Takeaway:

    Electrical Signature Analysis (ESA) can detect hidden performance issues across the entire motor-driven system—even when both electrical and mechanical components appear healthy—making it a powerful tool for identifying root causes like flow turbulence and improving predictive maintenance.

  • Ball Mill Monitoring Case Study: Avoiding R14.4M in Downtime with Infrared Technology

    How Infrared Monitoring Helped Avoid a Costly Ball Mill Failure

    In the mining industry, maintaining the reliability of critical equipment is essential to ensuring continuous production and minimizing costly downtime. One such critical asset is the ball mill, a key component in mineral processing operations where material size reduction is achieved through impact and attrition.

    In addition to Vibration and Lubrication monitoring Yellotec implemented thermal monitoring of the external mill shell to improve the condition monitoring of the inter mill wear lining. By combining manual and continuous thermal imaging technologies, the operation gained deeper insight into mill lining performance, wear patterns, and potential failure points.

    The Challenge

    Ball mills operate under extreme mechanical and thermal stress, leading to friction, misalignment and wear issues over time. Traditional inspections, often limited to shutdowns or manual checks, can result in missed early faults, unplanned downtime, higher maintenance costs, and reduced equipment lifespan.

    The Solution

    Yellotec deployed a dual approach using the FLIR T540 initially and then the fixed FLIR A70 camera with online software to provide continious monitoring of both primary and secondary mill liner conditions.

    Manual Thermal Inspections

    The FLIR T540 was used to conduct detailed thermal inspections of the mill during operation. These inspections enabled the team to:

    • Identify high wear patterns on both primary and secondary mills
    • Detect abnormal heat signatures linked to friction and liner degradation
    • Pinpoint areas of concern, requiring maintenance attention

    Thermal imaging revealed clear variations in temperature across the mill shell, highlighting zones of excessive wear that would not have been visible through conventional methods.

    Continuous Thermal Monitoring

    To enhance visibility even further, the FLIR A70 Smart Sensor was installed for real-time monitoring of the secondary mill. This provided:

    • Continuous thermal data of the mill shell
    • Early detection of temperature anomalies
    • Trend analysis for predictive maintenance planning

    With continuous thermal imaging, maintenance teams could monitor changes over time and respond to developing issues before they escalated into failures.

    Key Findings

    The implementation of thermal imaging uncovered several critical insights:

    • High wear patterns were identified on both primary and secondary mills
    • Temperature anomalies indicated uneven load distribution and potential internal issues
    • Secondary mill shell conditions were monitored in real time, improving decision-making

    These findings allowed for targeted maintenance interventions, reducing the need for reactive repairs.

    FLIR T540
    FLIR A70

    Results and Impact

    By integrating thermal imaging into their maintenance strategy, the operation achieved:

    • Improved asset reliability through early liner wear detection
    • Reduced unplanned downtime
    • Enhanced maintenance planning with data-driven insights
    • Significant cost avoidance by preventing major failures

    The ability to continuously monitor the mill without interrupting production marked a major shift toward greater reliance on predictive maintenance.

    Early detection of a potential shell failure prevented 72 hours of unplanned downtime, eliminating a major risk to production. While repair costs were minimal, the real impact was in avoiding an estimated R14.4 million in downtime-related losses.

    Conclusion

    Yellotec’s implementation of thermal imaging technology demonstrates how modern condition monitoring tools can transform maintenance strategies in the mining sector. By leveraging both manual inspections and continuous monitoring, operations can gain a comprehensive understanding of equipment health and act proactively.

    As mining operations continue to prioritize efficiency and uptime, thermal imaging is becoming an essential tool for maintaining a competitive edge.

  • Yellotec Partners with ReVibe Energy

    Yellotec is excited to announce a new partnership with ReVibe Energy, bringing innovative wireless, self-powered sensing technology to industries that rely on critical vibratory equipment.

    ReVibe Energy develops advanced vibration monitoring sensors that generate their own power by harvesting energy directly from machine motion. These wireless sensors require no batteries or cables, enabling continuous vibration monitoring in environments where traditional sensors are difficult to install or maintain. The technology is particularly well suited for vibrating screens and other high-vibration industrial equipment.

    Industrial vibrating screens play a critical role in sectors such as mining, aggregates, and mineral processing. These machines are used to sort, separate, and classify large volumes of material by size, operating under constant high vibration and heavy loads. Because of these demanding conditions, screens are subject to significant mechanical stress and wear, making reliable condition monitoring essential to prevent failures and unplanned downtime.

    However, the same high-energy environment that makes screens effective also makes them difficult to monitor using conventional sensors. Cabling can fail due to continuous movement, while battery-powered devices require frequent maintenance in hard-to-reach locations.

    ReVibe’s self-powered wireless sensors address this challenge by using the machine’s own vibration as an energy source. This allows sensors to operate continuously without external power, providing reliable vibration data that can be used to monitor screen performance, detect developing faults, and support predictive maintenance strategies.

    Through this partnership, Yellotec will introduce ReVibe’s innovative sensing solutions to help close this long-standing monitoring gap. By converting machine motion into actionable insights, the technology enables improved equipment reliability and greater operational visibility.

    By combining Yellotec’s expertise in machine condition monitoring with ReVibe’s self-powered sensor technology, customers will gain new capabilities to monitor equipment that was previously difficult or impossible to instrument.

    Yellotec is excited to partner with ReVibe Energy and looks forward to delivering this new generation of monitoring solutions to industry.

  • Vibration Diagnostics on a Turbo Generator Train

    Advanced Vibration Diagnostics Reveal the True Cause of Turbo-Generator Blade Failure

    This OROS application note details a root cause investigation into a blade failure on a 15 MW turbo-generator at BASF. After an overhaul, the machine experienced unexpected blade damage, prompting a comprehensive vibration and rotor dynamic analysis using advanced diagnostic tools.

    Tests ruled out speed instability, torsional resonance, and balancing issues. The investigation concluded that excessive steam extraction in the exhaust system caused blade excitation and failure, highlighting the importance of in-depth vibration diagnostics in turbomachinery.

    Read the Full Article

    Article Highlights:

    • Root cause investigation of a blade failure on a 15 MW turbo-generator at BASF.
    • Advanced vibration diagnostics performed using OROS analyzer and ORBIGate software.
    • Speed stability, torsional vibration, torque, and shaft centerline behavior were all analyzed.
    • No issues found with speed regulator, torsional resonance, or balancing.
    • Slow-roll vibration traced to turning gear eccentricity — not a fault condition.
    • Root cause identified as excessive steam extraction in the exhaust system, leading to blade excitation and damage.
    • Highlights the value of detailed rotor dynamic and vibration analysis in preventing unplanned downtime.

    Key Takeaway:

    Comprehensive vibration and rotor dynamic analysis is essential for accurately diagnosing turbomachinery failures — in this case at BASF, advanced diagnostics ruled out mechanical and control issues and revealed that excessive steam extraction caused the blade damage, demonstrating the importance of detailed data-driven investigation to prevent unnecessary downtime and misdiagnosis.

  • Webinar // Mining 4.0: Maximizing Uptime in Critical Machinery with Advanced Monitoring

    Join us for an insightful webinar focused on Mining 4.0 and how advanced condition monitoring is transforming the way mining operations protect critical machinery, reduce failures, and maximize uptime.


    As mining operations continue to push for higher productivity, safety, and cost efficiency, unplanned downtime remains one of the industry’s biggest challenges. Harsh operating conditions, aging assets, and increasing production demands make reliability more critical than ever.

    Agenda:

    • Overview of the current mining process
    • Identifying critical machinery
    • Why monitoring is key for uptime optimization
    • Success stories: Real-world impact

    Date and Time:

    • Wednesday, 4 March 2026
    • 07:00 AND 11:00 PM CET

    To better support our global audience, we will host three live sessions:

    • APAC (English): 7:00 AM (Spain time) – Speaker: Eneko
    • EMEA (English): 11:00 AM (Spain time) – Speaker: Bruno
    • LATAM / Spain (Spanish): 4:00 PM (Spain time) – Speaker: Marco

    Who Should Attend:

    • Mining operations and plant managers
    • Maintenance and reliability engineers
    • Condition monitoring and asset management teams
    • Anyone involved in improving uptime and equipment reliability
    Register here

  • Path to Excellence: Your guide to advancing in the field of Oil Analysis in 2026

    Discover how to advance your career in oil analysis and lubrication management with Yellotec’s specialised training and Noria-certified courses. Build practical skills, improve diagnostics, and strengthen equipment reliability through a structured path to excellence.

    In the world of machinery lubrication and oil analysis, standing still is not an option. As equipment becomes more complex and reliability expectations increase, the demand for skilled Oil Analysts and Oil Technicians continues to grow. Advancing your expertise doesn’t just benefit your career — it directly impacts maintenance performance, asset longevity, and operational efficiency.

    Whether you are building foundational knowledge or refining advanced diagnostic capabilities, continuous learning is the key to remaining relevant and effective in your role.

    The 3-Step Path to Oil Analysis Excellence

    1. Oil Analysis Series

    COMPREHENSIVE FOUNDATION

    Build your expertise from the ground up with a comprehensive training programme designed to equip professionals with the knowledge and practical skills required to implement and manage effective oil analysis programmes.

    This stage ensures you develop the technical confidence needed to apply best practices in real-world environments.

    2. Certified Training from Noria Corporation

    BECOME A CERTIFIED OIL ANALYST / TECHNICIAN

    Take your expertise to the next level by preparing for internationally recognized certification exams associated with:

    • International Council for Machinery Lubrication (ICML)

    Certification validates your knowledge, strengthens your credibility, and positions you as a trusted reliability professional. It demonstrates not only theoretical understanding but applied competence in lubrication and oil analysis practices.

    3. Skills Boosting Training

    KNOWLEDGE SUPPORT FROM NORIA

    Learning does not stop after certification. Continue strengthening your expertise with access to Noria Corporation’s expansive collection of world-class lubrication practices, research, and professional development tools.

    Gain knowledge support through:

    • Noria Publications
    • Noria Online Training
    • Access to LPD (Lubrication Program Development resources)

    This ongoing development ensures you remain current, competitive, and aligned with global best practices in lubrication and reliability.

    Why Advancing Your Skills Matters

    Oil analysis is far more than interpreting lab results. It is about understanding machine health, identifying early warning signs, and making informed maintenance decisions that prevent costly failures.

    By advancing your knowledge and practical ability, you can:

    • Deliver more accurate and confident diagnostics
    • Strengthen preventive and predictive maintenance strategies
    • Improve overall equipment reliability
    • Reduce unplanned downtime and associated costs
    • Add measurable value to your organization

    The difference between a competent technician and a trusted reliability professional often lies in structured training and certification.

    Your Structured Path to Excellence

    Yellotec’s Path to Excellence has been designed specifically for Oil Analysts and Oil Technicians who are serious about professional growth. The programme combines specialized, practical training with internationally recognized certification through Noria Corporation.

    This approach ensures you don’t just gain theoretical knowledge — you develop practical skills you can apply immediately in the field.

    Through this structured pathway, you will:

    • Strengthen your understanding of lubrication fundamentals
    • Improve sampling techniques and contamination control practices
    • Enhance your ability to interpret oil analysis results
    • Apply best practices in lubrication management
    • Build confidence in making data-driven maintenance decisions

    Globally Recognized Certification

    Certification validates your knowledge and demonstrates your commitment to professional excellence. Noria certifications are widely respected within the lubrication and reliability industry, providing a benchmark for competency and technical expertise.

    Earning certification not only boosts your credibility but also positions you for greater responsibility and career progression.

    From Technician to Trusted Expert

    The Path to Oil Analysis Excellence is designed to equip you with the skills, knowledge, and practical experience required to excel in oil analysis and lubrication management. It supports professionals at various stages of their careers — whether you are strengthening your foundation or preparing to step into a more strategic reliability role.

    Investing in your development is an investment in better diagnostics, smarter maintenance strategies, and more reliable assets.

    Enroll today and take your Oil Analysis expertise to the next level.

  • How 3 Minutes Can Prevent Motor Failure

    Quick Diagnostics That Save Time and Money: The Value of 3 Minutes of Motor Failure Testing



    This All-Test Pro article highlights a hospital motor failure where initial basic testing pointed to the drive as the issue.

    After replacing the drive without resolving the problem, a motor circuit analysis test quickly identified an internal motor fault, demonstrating how proper, fast diagnostics can prevent unnecessary costs, downtime, and repairs.

    Read the Full Article

    Article Highlights:

    • A 17 kW hospital roof fan motor in the Netherlands failed less than a year after installation.
    • Basic tests (insulation & resistance) showed no faults, so the VFD was replaced — but the issue remained.
    • The motor was later tested using the ALL-TEST PRO7™ (AT7™ PRO)   Motor Circuit Analysis tool.
    • In just 3 minutes, testing revealed an internal phase fault that standard tests missed.
    • The hospital incurred unnecessary costs (VFD replacement, crane rental, downtime).
    • Proper motor circuit testing can quickly identify real faults and prevent costly misdiagnosis.
    • Key message: A few minutes of advanced testing can save significant time, money, and downtime.

    Key Takeaway:

    Spending just about 3 minutes using a proper motor diagnostic tool like Motor Circuit Analysis (MCA) can identify the real cause of a motor failure—saving significant time, money, and unnecessary equipment replacements. In the case study, basic tests misled technicians and led to a faulty VFD replacement and costly motor removal, whereas a quick MCA test pinpointed the actual motor fault right away.