The verdict in three sentences
For a meat processing plant near Dublin with 3 lines and 450 assets, the main lever of a CMMS is cutting unplanned stoppages, because one hour of downtime costs EUR 5,000 to 15,000 in lost output, downgraded product and overtime. An off-the-shelf CMMS at EUR 40 to 90 per user per month is enough if your needs stay standard, while a custom tool at EUR 40,000 to 80,000 pays off once you want sensors, the cleaning schedule and BRCGS audit evidence in a single screen. On a site this size, avoiding 6 hours of downtime a year usually covers the investment.
What a CMMS must trace in a food plant
Food manufacturing adds constraints that general engineering does not have: cleaning and disinfection between shifts, food-grade lubricants, calibration of temperature probes, foreign body detection. A BRCGS Food Safety Issue 9 auditor checks that every job is planned, completed, signed off and that the asset is returned to production after a hygiene clearance.
| Function | BRCGS requirement or use | Measurable gain | Priority |
|---|---|---|---|
| Preventive maintenance plans | Frequencies per asset, detailed task lists | 30 to 45 % fewer unplanned stoppages | High |
| Mobile work orders | Timestamped traceability, technician signature | 20 min of data entry saved per order | High |
| Hygiene clearance after work | Quality sign-off before restart | Zero major non-conformities on this point | High |
| Instrument calibration | Probes, scales, metal detectors | Certificates found in 2 min during audit | High |
| Sensors and drift alerts | Vibration, temperature, motor current | Detection 2 to 3 weeks before failure | Medium |
| Spare parts management | Minimum stock, critical spares | 15 to 25 % less dead stock | Medium |
| OEE and MTBF indicators | Steering by line and shift | Costed investment decisions | Medium |
Off-the-shelf CMMS or custom tool: 2026 prices
| Criterion | Off-the-shelf CMMS (SaaS) | Custom CMMS |
|---|---|---|
| Initial cost | EUR 3,000 to 12,000 (setup, import) | EUR 40,000 to 80,000 |
| Subscription | EUR 40 to 90 per user per month | Hosting EUR 150 to 400 per month |
| Annual cost for 25 users | EUR 12,000 to 27,000 | EUR 8,000 to 14,000 (support + hosting) |
| Time to go live | 6 to 12 weeks | 4 to 6 months |
| Sensor and PLC connection | Generic connectors, often paid | Direct integration with your PLCs and gateways |
| Specific BRCGS workflows | Partly configurable | Built around your HACCP plan |
| Data ownership | Export to negotiate | Database and code delivered |
The sensor budget is separate: count EUR 150 to 400 per wireless measuring point (vibration and temperature), plus a EUR 1,500 gateway. Fitting the 40 critical assets costs about EUR 10,000 to 18,000. There is no need to instrument all 450 assets: focus on mincers, fillers, blast chillers, refrigeration compressors and packing machines.
Rollout in four steps
- Inventory and criticality (4 weeks): coding the 450 assets, ranking them A, B, C by impact on output and food safety.
- Preventive task lists (6 weeks): importing existing plans, frequencies, standard times, hygiene instructions.
- Development and mobile (8 to 12 weeks): work orders on rugged tablets, quality sign-off, dashboards.
- Sensors and alerts (4 weeks): drift thresholds, notifications to the shift lead, automatic creation of a preventive order.
Mini case study
Siobhan, maintenance manager of a cooked meats plant near Dublin, runs 3 lines and 450 assets with 14 technicians. Last year she suffered 22 hours of unplanned stoppage on the slicing line, at about EUR 9,000 an hour, i.e. EUR 198,000 in losses. The custom project is quoted at EUR 62,000, plus EUR 14,000 of sensors on 45 points and EUR 11,000 a year for maintenance and hosting.
Targeting a 40 % reduction in unplanned stoppages, she would save about 8.8 hours, i.e. EUR 79,200 a year. The full project (EUR 76,000 in year one) pays back in under 12 months, not counting the time saved preparing the BRCGS audit, estimated at 5 days a year for the technical manager (2026 order of magnitude).
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FAQ
What does a CMMS cost for a food processing plant?
An off-the-shelf CMMS costs EUR 40 to 90 per user per month, i.e. EUR 12,000 to 27,000 a year for 25 users. A custom tool requires EUR 40,000 to 80,000, then EUR 8,000 to 14,000 a year.
Does a CMMS really help pass a BRCGS audit?
Yes, if it traces hygiene clearance after every job and stores calibration certificates. Maintenance-related findings often account for 10 to 20 % of non-conformities raised in audits.
Do all assets need sensors?
No, 30 to 50 critical assets are enough in a plant with 450 assets. At EUR 150 to 400 per point, the budget stays under EUR 20,000.
How long does rollout take?
Allow 4 to 6 months for a custom tool, including 4 weeks of inventory. A SaaS can run in 6 to 12 weeks if preventive task lists already exist.
Can technicians log work without signal in chilled rooms?
Yes, the mobile app works offline and syncs when leaving the area. IP67 rugged tablets cost EUR 600 to 1,100 each.
Let's scope your project. We scope your CMMS (inventory, task lists, mobile, sensors), with an indicative budget of EUR 40,000 to 80,000 and go-live in 4 to 6 months. Detailed quote within 48 h. WhatsApp +221 77 596 93 33.
Mohamed Bah
Fondateur, Kolonell
Passionate about digital and entrepreneurship in Africa, Mohamed has been helping Sénégalese businesses with their digital transformation since 2020. Founder of Kolonell, he believes every SME deserves a professional and accessible online présence.
