Case studies
What we found, what it cost, and what changed.
Have a look around. These are projects at factories a lot like yours, and a few of them are probably down the road from you. Each one runs the same way: the alert nobody was watching for, what it was costing, the fix, and the meter afterwards.
Filter by what we measure, by sector, or both.
Sector9
All 19 case studies
No case study matches that combination yet. to see all 19.
Predictive maintenanceWaterBreweries & Beverage
A failing diaphragm pump, caught before it failed
Carlsberg Canada
A failing diaphragm pump caught before it failed, and 540,000 L/day of loss prevented.
540,000 Lper day
WaterBreweries & BeverageFood & Beverage Processing
Pasteurizer water down from 28.0 to 5.5 m³/day
Carlsberg Canada
Pasteurizer water down from 28.0 to 5.5 m³/day, and $38,400 a year with no capital cost.
$38,400per year
Compressed airWaterFood & Beverage ProcessingBulk Handling & Rail Logistics
Over 450,000 litres saved in four months, and the clearest compressor graph we've produced
PDI Bulk
>450,000 litres of water saved in four months, and the clearest before/after compressor graph we've ever produced.
>450,000 Lin 4 months
WaterManufacturing: automotive, plastics & rubber
Chiller circuit leak isolated without a shutdown
An automotive factory
A leaking cooling loop found and isolated with the line still running.
1 loopisolated
Temperature & humidityFood & Beverage ProcessingControlled Environment Agriculture (Greenhouses)
A cold-storage alert at two in the morning
A cold storage operation
A refrigeration fault caught overnight, before the product was.
2 a.m.alert
Compressed airManufacturing: automotive, plastics & rubberMetal Fabrication & Finishing
Compressed air leaks in a stamping operation
A Tier 2 automotive stamping factory
The most expensive utility per unit of work, leaking into an empty building overnight.
20–30%of compressor output
Predictive maintenanceBulk Handling & Rail LogisticsManufacturing: automotive, plastics & rubber
Conveyor drive bearing degradation caught six weeks early
A bulk handling facility
A bearing changed its signature about six weeks before it would have seized.
6 weeksof warning
Cooling towersWaterManufacturing: automotive, plastics & rubberBuilding Materials, Concrete & Aggregates
Cooling tower blowdown optimization
A plastics manufacturing factory
Blowdown running on a timer instead of on conductivity, discharging good water.
1 setpointchanged
Compressed airNatural gasMetal Fabrication & FinishingBuilding Materials, Concrete & Aggregates
A furnace over-cycling, seen on the air and gas traces together
A heat-treating operation
Short-cycling that neither the gas bill nor the air system showed alone.
2 utilitieson one chart
Energy & electricityBulk Handling & Rail Logistics
Night setback that never happened
A distribution warehouse
The overnight setback had silently stopped working, and it was worth about a third of the load.
~35%of overnight electrical load
Natural gasBuilding Materials, Concrete & AggregatesManufacturing: automotive, plastics & rubber
A 1970s boiler brought onto the dashboard
A heavy manufacturing factory
A fifty-year-old boiler, integrated through its 4-20 mA output. Nothing was ripped out.
4-20 mAintegration
Energy & electricityManufacturing: automotive, plastics & rubber
Three factories, one unit of production, one outlier
A manufacturer with three factories
Same product, same equipment, and one factory used about 40% more energy per unit.
~40%more energy per unit
Predictive maintenanceMunicipal & Public Utilities
Pump cavitation caught three weeks early
A municipal water facility
The vibration signature changed about three weeks before anyone would have heard it.
3 weeksof warning
Cooling towersEnergy & electricityFood & Beverage ProcessingControlled Environment Agriculture (Greenhouses)
Refrigeration condenser fouling detection
A food storage and processing site
Rising head pressure at constant load: a fouled condenser, priced.
Head pressurevs. load
Silo & levelFood & Beverage ProcessingControlled Environment Agriculture (Greenhouses)
Silo level early warning at the reorder threshold
An ingredient handling operation
Non-contact radar level, continuous, with a low-level alert before the reorder deadline.
0silo climbs
Natural gasPharmaceutical & ChemicalFood & Beverage Processing
Steam trap failure monitoring
A pharmaceutical manufacturing site
A failed-open steam trap vents energy continuously and silently.
Continuousmonitoring
Silo & levelPharmaceutical & ChemicalMunicipal & Public UtilitiesBulk Handling & Rail Logistics
Tank level and inventory reconciliation
A bulk chemical storage operation
Measured tank level reconciled against what the paperwork said was in there.
Continuousreconciliation
WaterFood & Beverage Processing
Weekend ghost flow in an empty building
A food processing factory
Water still running through an empty factory all weekend, worth about a fifth of the monthly bill.
~20%of the monthly water bill
Temperature & humidityMetal Fabrication & FinishingManufacturing: automotive, plastics & rubber
Welding bay CO and CO₂ monitoring
A metal fabrication shop
Air quality in the welding bay, watched continuously instead of checked quarterly.
Continuousvs. quarterly
| A failing diaphragm pump, caught before it failed | Carlsberg Canada | Predictive maintenance, Water | 540,000 L per day |
| Pasteurizer water down from 28.0 to 5.5 m³/day | Carlsberg Canada | Water | $38,400 per year |
| Over 450,000 litres saved in four months, and the clearest compressor graph we've produced | PDI Bulk | Compressed air, Water | >450,000 L in 4 months |
| Chiller circuit leak isolated without a shutdown | An automotive factory | Water | 1 loop isolated |
| A cold-storage alert at two in the morning | A cold storage operation | Temperature & humidity | 2 a.m. alert |
| Compressed air leaks in a stamping operation | A Tier 2 automotive stamping factory | Compressed air | 20–30% of compressor output |
| Conveyor drive bearing degradation caught six weeks early | A bulk handling facility | Predictive maintenance | 6 weeks of warning |
| Cooling tower blowdown optimization | A plastics manufacturing factory | Cooling towers, Water | 1 setpoint changed |
| A furnace over-cycling, seen on the air and gas traces together | A heat-treating operation | Compressed air, Natural gas | 2 utilities on one chart |
| Night setback that never happened | A distribution warehouse | Energy & electricity | ~35% of overnight electrical load |
| A 1970s boiler brought onto the dashboard | A heavy manufacturing factory | Natural gas | 4-20 mA integration |
| Three factories, one unit of production, one outlier | A manufacturer with three factories | Energy & electricity | ~40% more energy per unit |
| Pump cavitation caught three weeks early | A municipal water facility | Predictive maintenance | 3 weeks of warning |
| Refrigeration condenser fouling detection | A food storage and processing site | Cooling towers, Energy & electricity | Head pressure vs. load |
| Silo level early warning at the reorder threshold | An ingredient handling operation | Silo & level | 0 silo climbs |
| Steam trap failure monitoring | A pharmaceutical manufacturing site | Natural gas | Continuous monitoring |
| Tank level and inventory reconciliation | A bulk chemical storage operation | Silo & level | Continuous reconciliation |
| Weekend ghost flow in an empty building | A food processing factory | Water | ~20% of the monthly water bill |
| Welding bay CO and CO₂ monitoring | A metal fabrication shop | Temperature & humidity | Continuous vs. quarterly |
Your factory is next.
Thirty minutes, your utility bills, and an honest read on what is worth metering first. If we don’t think a project will pay for itself we will tell you that too, and it is a short conversation either way.
There are two things worth taking from these. One is the money: the leak, the compressor, the overnight load, the fix and what it was worth. The other is production visibility, which is harder to put on an invoice and is often what a factory ends up leaning on. If one of these is close to your situation, tell us which and we’d be happy to connect you with the people at that factory.
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