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How to Prevent 6 Hours of Plant Downtime – A $270,000 Daily Production Loss

Oct 14, 2025 - Laurentide How Predictive Maintenance Can Help Prevent 6 Hours of Plant Downtime - A $270,000 Daily Production Loss 2 Critical Downtime

October 14, 2025

Critical Downtime & Production Loss: How to Prevent Maintenance Issues with Reliable Partners & Effective Solutions

In today’s fast-paced and sustainability-driven industrial landscape, minimizing downtime is not just a priority—it’s a necessity. For one of Laurentide’s clients in the asphalt industry, a sudden plant shutdown due to damaged instruments posed a severe threat to both their financial stability and environmental compliance. 

A Race Against Time for Their Client

When the critical instrument on the burner system failed, the consequences were immediate and severe: 

  • Complete plant shutdown for 6 hours: resulting in halted production. 
  • Daily production losses of $270,000. 
  • Environmental risk due to increased emissions from asphalt production. 
  • Potential penalties of $10,000 per day from government agencies. 
  • Missed project deliveries for clients.

Adding to the complexity, the delivery time for an identical replacement was an unworkable 8 weeks, leaving the client searching for better solutions. Multiple internal teams were mobilized to address the issue, but the risk of prolonged downtime continued to escalate. 

Oct 14, 2025 - Laurentide How Predictive Maintenance Can Help Prevent 6 Hours of Plant Downtime - A $270,000 Daily Production Loss 2 Critical Downtime

How Could Laurentide Help?

As the official representatives for Rosemount instruments, Laurentide takes pride in offering expertise and maintaining a well-stocked local inventory to meet their clients’ needs. Over the past year, Laurentide’s account manager has worked closely with the client, building a strong relationship through regular visits and personalized support. When faced with a challenge, the client trusted their skilled and dedicated technicians to provide reliable solutions, reinforcing the value of their partnership. 

When Efficiency Meets Expertise

Within 2 hours of the issue being flagged, the Laurentide team collaborated with their clients’ different on-site teams to deliver a seamless solution: 

  • Rapid On-Site Response: Laurentide’s technician was on-site in under 2 hours to assess, install, and test the replacement equipment. 
  • Innovative Inventory Solution: Utilizing two locally available inventory parts, Laurentide replaced the damaged unit with: 
    • Coriolis Flow Transmitter, Model 5700 Advanced (P1105798).
    • Micro-Motion 9-wire Remote Enhanced Core Processor (P1059357).
Oct 14, 2025 - Laurentide How Predictive Maintenance Can Help Prevent 6 Hours of Plant Downtime - A $270,000 Daily Production Loss 3 Critical Downtime

The immediate result was a production restart at the plant, which operates at 300 metric tons per hour, valued at $90 CAD per ton. This swift action minimized downtime and avoided what could have been catastrophic financial and environmental consequences.  

The Benefits for Their Client: Quantifiable Results

Laurentide’s intervention prevented a prolonged shutdown that could have spiraled into millions of dollars in losses for their client: 

  • $162,000 saved in lost production during the 6-hour downtime. 
  • Health and Safety Benefits: By resolving the issue quickly, Laurentide reduced prolonged exposure risks for the client’s internal teams, safeguarding their health and safety. 
  • Avoided 12 days of potential downtime, which would have cost: 
    • $3.24 million in lost production revenue. 
    • $120,000 in penalties from government and client contracts. 

Laurentide: Delivering Results When It Matters Most 

At Laurentide, they prioritize efficiency, technical expertise, and maintaining a reliable local inventory to meet their clients’ needs. When faced with a critical challenge, their rapid response and innovative solutions helped deliver results in hours. This not only created significant cost savings for their client but also strengthened their confidence in Laurentide as a trusted partner during critical moments. 

A $3.36 Million Loss Value Prevented

Had the Laurentide team not acted as quickly as they did, the total financial impact for the client would have been estimated at $3.36 million in losses. By stepping in with precision and speed, they turned a potential disaster for their client into minimized loss and a rapid plant operations restart.  

At Laurentide, they aim to empower their clients to stay competitive and resilient in the face of challenges. Predictive maintenance solutions enhance systems and assist in preventing downtime with real-time status and equipment performance updates, which enables the maintenance issues to be addressed before downtown is required.

For more information on Laurentide Solutions HERE

Oct 14, 2025 - Laurentide How Predictive Maintenance Can Help Prevent 6 Hours of Plant Downtime - A $270,000 Daily Production Loss Critical Downtime

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