Predictive Maintenance:
Equipment-Specific Solutions
Compressed Air Systems
Common Liabilities:
Undetected air leaks waste energy and increase load
Bearing wear leads to motor or rotor failure
Moisture traps fail, causing internal corrosion
VFD issues or phase imbalance reduce efficiency
Predictive Maintenance Solutions:
Ultrasonic leak detection with quantified loss per leak
Vibration and motor circuit testing for early fault detection
Monitoring dew points and dryer performance trends
Power quality and thermal testing of control panels and VFDs
Conveyor Systems
Common Liabilities:
Motor or gearbox failures halt production lines
Misalignment causes belt wear and tracking issues
Bearing failure leads to seized rollers or chain damage
Chain slack or lubrication failure causes erratic movement
Predictive Maintenance Solutions:
Vibration analysis on motors, rollers, and reducers
Ultrasonic inspection for bearing and gear lubrication
Thermography to detect overheating or misalignment
Shaft alignment and chain tension verification
Boilers & Steam Traps
Common Liabilities:
Failed traps cause condensate backup or live steam loss
Undetected leaks raise energy and chemical costs
Water hammer damages pipes and valves
Pressure or temperature fluctuations disrupt processes
Predictive Maintenance Solutions:
Ultrasound inspection of steam traps (per ISO 7841)
Thermal imaging of trap function and valve temperature
Leak surveys to locate failed piping and insulation
Trending of pressure and flow data for anomaly detection
Power Control & Distribution
Common Liabilities:
Overheating at connections causes fire risk or arc flash
Phase imbalance or voltage sag damages motors and VFDs
Loose terminals degrade over time and cause failure
Nuisance trips from harmonics or transient events
Predictive Maintenance Solutions:
Infrared thermography of breakers, lugs, and relays
Power quality analysis (voltage/current harmonics, imbalance)
Ultrasonic detection of arcing or partial discharge
Real-time load monitoring and trend analysis
Freezers / Refrigeration
Common Liabilities:
Coil icing or defrost failure damages product
Fan motor failure compromises air circulation
Leaking seals or insulation gaps raise energy cost
Compressor or expansion valve failure causes temperature drift
Predictive Maintenance Solutions:
Thermal imaging of coils, compressors, and airflow zones
Ultrasound inspection for refrigerant or vacuum leaks
Vibration analysis on motors and compressor bearings
Temperature and cycle monitoring for early alerts
Injection Molding
Common Liabilities:
Hydraulic failures cause shot repeatability issues
Heater band failure disrupts material flow
Mold misalignment leads to part defects
Mechanical wear causes slow cycle times or jams
Predictive Maintenance Solutions:
Vibration testing of hydraulic pumps and motors
Thermography on heater bands and control cabinets
Shaft alignment verification and tie-bar inspection
Oil analysis for contamination and viscosity breakdown
Industrial Ovens
Common Liabilities:
Heater bank failure causes uneven temperatures
Insulation degradation increases energy loss
Fan motor or drive failure results in hot spots
Thermocouple drift affects bake profiles and quality
Predictive Maintenance Solutions:
Infrared thermography of heating elements and ducting
Vibration and current analysis of circulating fans
Thermal envelope inspection to identify insulation loss
Temperature uniformity testing and zone control trending
Packaging & Sorting
Common Liabilities:
Labelers and sealers misfire from component wear
Timing issues in sorters create jams or misroutes
Air leaks reduce cylinder response in pneumatics
VFD faults slow production or cause drift
Predictive Maintenance Solutions:
Ultrasound inspection of pneumatic systems and leaks
Vibration analysis on drives, cams, and conveyors
Encoder and sensor signal validation with oscilloscope tools
Thermography of motors and drives under load
Pump Systems
Common Liabilities:
Seal or bearing failure causes leaks or seizures
Cavitation from poor NPSH or valve failure
Misalignment or imbalance reduces efficiency
Motor overload from worn impellers or binding
Predictive Maintenance Solutions:
Vibration and phase analysis for cavitation and wear
Motor circuit testing for insulation or rotor faults
Shaft alignment and coupling health checks
Flow and pressure monitoring for early deviation alerts
UPS / Power Backup Systems
Common Liabilities:
Battery degradation reduces run time without warning
Inverter or rectifier failures compromise power quality
Thermal runaway or arc faults pose safety risks
Load test failures leave critical systems exposed
Predictive Maintenance Solutions:
Thermography of batteries, connections, and heat sinks
Power quality analysis of voltage regulation and harmonics
Load testing and impedance checks on battery strings
Ultrasonic detection of corona, arcing, and partial discharge