This guide compiles what we have learned across hundreds of PET-line PM cycles in Qatar, the UAE, Saudi Arabia, and India. It's organised by sub-system, with realistic intervals, common fault patterns, and OEE impact estimates.
1. Blower (stretch-blow moulder)
Daily checks (operator level)
- Visual inspection — preform feeder, oven entry, mould area
- Compressed-air pressure reading (HP and LP)
- Chilled-water temperature and flow
- First-shift bottle quality check (wall thickness, base, neck)
Weekly
- Oven lamp visual inspection — replace any blackened lamps
- Stretching cylinder check (no leaks, smooth motion)
- Mould cleaning at format change
Monthly
- Stretching rod inspection and lubrication
- Preform-feed track wear inspection
- Air-filter element check (per Donaldson schedule)
- HP and LP air-quality dewpoint check
Quarterly
- Oven calibration and lamp positioning audit
- Reflector cleaning
- Mould-cooling circuit balance check
- Blow-valve seat inspection
- Bottle quality statistical capability study
Annual
- Full oven assembly inspection and reflector overhaul
- Stretching system rebuild (cylinders, valves, sensors)
- Blow-valve overhaul or replacement
- Preform gripper full inspection
- HP filter housing inspection and element refresh
2. Filler & capper
Weekly
- Underfill range observation (statistical sample)
- Capper torque sample (10 bottles)
- CIP cycle completion verification
Monthly
- Filler valve seal-kit inspection
- Capper jaw inspection
- Bottle-grip wear inspection
Quarterly
- Underfill statistical capability study (Cpk reported)
- Capper torque capability study
- Sterile-air filter inspection (aseptic lines)
Annual
- Filler valve full overhaul or seal-kit replacement
- Capper jaw refurbishment or replacement
- Aseptic-zone validation (where applicable)
- Filler control-system audit
3. Labeller
Weekly
- Glue-roller condition check (roll-fed)
- Label web tension and registration check (PSL)
- Brush-station condition
Quarterly
- Cutter blade replacement (roll-fed)
- Dispenser plate inspection (PSL)
- Squeegee resurfacing
4. Conveyors & end-of-line
Monthly
- Mat-top chain tension check
- Air-conveyor blower amp draw and pressure
- HEPA filter check on air conveyors
Quarterly
- Wrapper sealing-bar element check
- Case-packer end-effector inspection
- Palletiser robot calibration verification
5. Utilities — compressed air, water, steam
Compressed air (HP and LP)
- Weekly: filter pressure-drop reading
- Quarterly: dewpoint certification
- Annual: full Donaldson element refresh on schedule
Process water
- Weekly: TDS, pH, free chlorine
- Monthly: RO membrane CIP (per recovery and pressure-drop trend)
- Quarterly: UV lamp intensity check
OEE benchmarks (GCC plants, our 2025 data)
- Bottled water PET line (single-format): top-quartile 90%+, median 78-84%
- CSD multi-format line: top-quartile 80-85%, median 65-72%
- Hot-fill juice line: top-quartile 75-80%, median 58-65%
If your line is at the median, there's almost always a 5-10 OEE points available with structured PM and oven-energy tuning.
What goes into a documented PM programme
- Master PM calendar — every machine, every interval, every PM type
- Per-PM SOPs — written, peer-reviewed, version-controlled
- Parts and consumables matrix per PM
- Skills matrix — who is qualified to perform what
- Records — every PM event with date, technician, parts used, observations
- Trend analysis — review monthly, look for creeping fault patterns