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Manufacturing plant achieves 100% on-time preventative maintenance

Challenge

A large manufacturing plant in the eastern United States covers hundreds of acres and produces a wide range of products. However, its aged HVAC equipment frequently broke down, resulting in significant downtime as well as thousands of hours in maintenance and repairs.

With plant production and budget at risk, the organization needed a new provider—one who could keep stakeholders informed, gain a deep understanding of the site and assets, respond quickly and effectively, get repairs right the first time, and deliver valuable expertise. The customer needed a partner who could become a trusted extension of their own team.

Solution

After assessing the plant’s needs and working with stakeholders to develop measurable KPIs, Johnson Controls and the manufacturer launched an Asset Lifecycle Management Program. This program was designed to restore the HVAC equipment to working order, and then ensure a programmatic response to operations and maintenance. The program requires expert coordination of people, processes and technology to deliver the customer’s specified outcomes.

Results

Johnson Controls helped the manufacturing plant achieve measurable success within six months.

  • Uptime over 90%, improving estimated production output by a remarkable $40M
  • 50% reduction in annual maintenance and repair hours, saving $773,280
  • 100% on-time preventative maintenance, extending asset life
  • Estimated $5M+ to bottom-line profitability
 

Johnson Controls Industrial Solutions

At Industrial Equipment Company, we are proud to partner with Johnson Controls, a global leader in building automation, HVAC, and industrial control solutions. With a legacy spanning over 135 years, Johnson Controls is committed to creating smarter, safer, and more sustainable industrial environments through cutting-edge technology and innovative engineering.

Innovative Industrial Solutions

Johnson Controls delivers a broad range of products and solutions designed to optimize efficiency, enhance safety, and reduce operational costs. Their expertise spans various industries, including manufacturing, energy, commercial buildings, and infrastructure development.

Our Featured Johnson Controls Products:

  • HVAC Systems & Controls – Advanced heating, cooling, and ventilation solutions designed for optimal performance and energy savings.

  • Building Automation & Management Systems – Intelligent controls that improve operational efficiency and enhance security.

  • Fire & Life Safety Systems – Cutting-edge fire detection and suppression technologies ensuring workplace safety.

  • Energy Storage & Power Solutions – Innovative battery technologies for reliable backup power and energy efficiency.

  • Industrial Refrigeration – High-performance cooling and refrigeration solutions tailored to industrial needs.

Why Choose Johnson Controls?

  • Proven Reliability: Decades of experience delivering high-quality industrial solutions.

  • Smart Technology: Integration of AI and IoT for intelligent automation and monitoring.

  • Energy Efficiency: Solutions designed to reduce energy consumption and operational costs.

  • Sustainability Commitment: Eco-friendly innovations to support greener industrial practices.

Find the Right Solution for Your Business

At Industrial Equipment Company, we help businesses implement Johnson Controls solutions tailored to their specific operational needs. Whether you’re looking for advanced HVAC systems, building automation, or energy-efficient power solutions, we have the expertise to support your success.

Contact us today to explore how Johnson Controls can enhance your industrial operations!

The Importance of Motor Testing

The Importance of Motor Testing

OPTIMIZING BUSINESS OPERATIONS 

 

Electric motors are essential to all industries, from wastewater treatment to steel manufacturing to automotive and power generation. Depending on the system, electric motors can use dozens or even hundreds of parts that need constant maintenance to keep them spinning effectively – investing time into preventative measures essential for protecting operations. 

 

Integral to the success and efficiency of your business is electric motor testing. ALL-TEST Pro instruments provide comprehensive motor health analyses beyond standard testing methods to ensure the health of those motors.

 

All-Test Pro advanced motor analysis devices alleviate the stress from unpredictable motor failures so your business stays up and running. The product line covers transformers, electric motors, and generators.  

 

Megohmmeter insulation testing only detects faults to ground. Since only a portion of motor electrical winding failures begin as ground faults, they will go undetected using this method alone. Moreover, surge testing requires the application of high voltages, which can be destructive when testing a motor, making it an unsuitable method for troubleshooting and accurate predictive maintenance testing.

 

ALL-TEST Pro devices provide more comprehensive diagnostics of your motor’s health than any other device on the market.

 

WHY MOTORS FAIL AND HOW TO PREVENT IT

 

Electric motors require regular maintenance. Industries that use machines 24/7/365 create stress on connections, fuses, and bearings. Even new motors can suffer from power surges, putting you out of commission for weeks.

Electric motors typically showcase small, compact housings where heat becomes trapped. In addition, excess vibration and fluctuating temperatures weaken insulation and motor hardware, increasing the chance of motor failure. Over time, motors also require thorough cleanings to eliminate debris.

 

MOTOR TESTING IMPORTANCE

 

Professionals often think systems must be in order if a motor sounds like it’s working. Unfortunately, this is only sometimes the case. Motor failures can happen when your team least expects it.

 

In addition, not all winding faults start as ground faults. Instead, they can begin as a weakness in the winding insulation system that may eventually fault to ground when the motor stops running.

 

Motor testing is integral to the success and efficiency of your business. ALL-TEST Pro instruments ensure that testing your motor is safe, easy, and dependable. In addition, our troubleshooting and predictive maintenance capabilities sustain critical systems and achieve meaningful ROI.

 

ALL-TEST Pro provides hand-held diagnostic devices for testing key motor components.

 

WHY TRADITIONAL MEGOHMMETER TESTING ISN’T ENOUGH

 

Megohmmeter insulation testing only detects faults to the ground. Since only a portion of motor electrical winding failures begin as ground faults, they will go undetected using this method alone. In addition, surge testing requires the application of high voltages, making it an unsuitable method for troubleshooting and predictive maintenance testing.

 

ALL-TEST Pro devices offer more complete motor testing than any other option on the market. Going above and beyond standard testing equipment for accurate, safe, fast motor testing. Using an MCATM tool takes less than three minutes, saving time and money by proactively detecting developing faults before they cause irreversible motor failures.

 

BENEFITS OF ALL-TEST PRO DEVICES

 

While traditional tools, such as a megohmmeter, cannot detect small developing winding faults, All-Test Pro devices, such as the ALL-TEST PRO 7™, provide comprehensive, accurate information of the winding insulation, winding insulation to ground, and rotor.

 

All-Test Pro Motor Testing

 

Benefits include:

 

  • Hand-held (usable in any environment)
  • Provide 6+ Diagnostic Readouts (as opposed to current Megohmmeters with only 1)
  • Easy to Operate
  • Responsive Customer Support

All Test Pro devices offer comprehensive motor testing that can help keep your business up and running. You’ll avoid costly interruptions by ensuring that your products and services operate smoothly. 

 

If you’re curious about the advantages of All-Test Pro, contact your local Industrial Equipment Company Representative for a demonstration. You’ll see firsthand how this outstanding solution can work wonders in reducing downtime and improving productivity.

Getting The Most Out Of Hotstart Heaters

Getting The Most Out Of Hotstart Heaters

Getting The Most Out Of Hotstart Heaters

Maximize Efficiency | HOTSTART Heaters

If you’re looking for a reliable and effective way to keep your engine operating at peak performance, HOTSTART heaters are a perfect solution; essential to keeping engines operating at peak performance, regardless of ambient temperature. 

HOTSTART has been manufacturing heating systems since 1942, serving markets from backup power generation to construction to railway and marine. Working with OEMs and aftermarket buyers looking to protect equipment from frigid temperatures, they offer systems as simple as an engine block heater to combinations that can warm coolant, hydraulics, and engine oil as needed. 

HOTSTART heaters are designed to prolong engine life, reduce downtime, and increase fuel efficiency – which means they pay for themselves over time. 

HOTSTART offers a variety of products to meet all your engine-related heating needs, including:

  • Temperature controls – to ensure optimal engine performance, regardless of the weather conditions
  • Magnetic contactors – for easy installation and hassle-free operation
  • Junction boxes – to protect your wiring from the elements
  • Wiring harnesses – for a clean, professional installation
  • Power cords – for convenient power delivery
  • Complete control systems – for ultimate peace of mind

Each type of product serves a different but essential purpose in ensuring the proper and efficient performance of coolant and lube oil heaters.

Benefits of Using HOTSTART Heaters

  • Improved engine performancele=”font-weight: 400;”>>: Hot oil and coolant reduce wear on engine components, improve fuel economy, and extend engine life.
  • Reduced emissions</b>: Help your business meet emissions standards by reducing unburned hydrocarbons and carbon monoxide in exhaust gases.
  • ass=”yoast-text-mark” style=”font-weight: 400;”>ia-level=”1″>Increased safety: HOTSTART heaters eliminate cold starts, which reduces the risk of engine damage and fires.
  • evel=”1″>Improved reliability</b>: Continuous heating, even during periods of extended downtime, so you can be confident that your engines will start when you need them to.
  • Enhanced profitability: HOTSTART heaters help improve your bottom line by reducing downtime and maintenance costs.

HOTSTART offers a wide range of products to meet all your engine-related heating needs. These products can help improve engine performance, reduce emissions, increase safety, and enhance profitability. So if you’re looking for ways to improve and protect your industrial business, consider investing in HOTSTART heaters today.

Markets served: Power Generation, Hazardous Location, Heavy Equipment, Truck & Bus

 

 

Preferred Utilities MFG

Preferred Utilities MFG

Preferred Utilities MFG

With over 100 years of industry history to draw from, Preferred Utilities MFG is uniquely positioned to help reduce emissions and increase efficiencies to meet the sustainability targets of the future. Their expertise ranges from fuel oil handling systems and components, boiler instrumentation and controllers, cutting-edge remote monitoring systems,  low- and ultra low-NOx burners, renewable and bio-fuel burners, specialty combustion applications like waste fuel, and nuclear power plant outage reduction tools and components. 

Preferred’s continuous research and development equips you with new and innovative solutions to meet the challenges of the modern world. Preferred products and custom-engineered solutions have been applied to a wide variety of applications, including economic retrofits for residential housing projects, redundancy solutions for mission-critical facilities like hospitals and data centers, emissions reductions for forward-thinking educational centers and institutions, as well as energy and electrical efficiency applications for boiler rooms all across the world. 

We’re confident that by partnering together, we can deliver the right people, products, and results to help you make the world a better place.

Preferred Utilities