Case studies
What the data revealed — and what changed next.
Explore monitoring projects from Canadian facilities across manufacturing, food and beverage, agriculture, logistics and public utilities.
Filter the case studies by measurement type, industry or both. Each project began with a site walk to understand the process and choose where to measure first.
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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 use reduced from 28.0 to 5.5 m³/day
Carlsberg Canada
Pasteurizer water use fell from 28.0 to 5.5 m³/day, producing approximately $38,400 in annual savings through operational changes alone.
$38,400per year
Compressed airWaterFood & Beverage ProcessingBulk Handling & Rail Logistics
More than 450,000 litres saved in four months
PDI Bulk
PDI Bulk saved more than 450,000 litres of water in four months and produced a clear before-and-after view of compressor performance.
>450,000 Lin 4 months
WaterManufacturing: Automotive, Plastics & Rubber
Chiller circuit leak isolated without a shutdown
An automotive factory
Continuous monitoring helped identify and isolate a leaking cooling loop while the production line remained in operation.
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 was detected overnight, before product temperature was affected.
2 a.m.alert
Compressed airManufacturing: Automotive, Plastics & RubberMetal Fabrication & Finishing
Compressed air leaks in a stamping operation
A Tier 2 automotive stamping factory
Permanent monitoring revealed compressed air continuing to flow into an otherwise idle building overnight.
20–30%of compressor output
Predictive maintenanceBulk Handling & Rail LogisticsManufacturing: Automotive, Plastics & Rubber
Conveyor-drive bearing degradation detected six weeks before failure
A bulk handling facility
The bearing’s vibration signature began changing approximately six weeks before the projected failure point.
6 weeksof warning
Cooling towersWaterManufacturing: Automotive, Plastics & RubberBuilding Materials, Concrete & Aggregates
Cooling tower blowdown optimization
A plastics manufacturing factory
Blowdown was controlled by a timer rather than conductivity, causing usable water to be discharged unnecessarily.
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
Head pressure rose while load remained constant, revealing condenser fouling and quantifying its energy cost.
Head pressurevs. load
Silo & levelFood & Beverage ProcessingControlled Environment Agriculture (Greenhouses)
Silo-level alert before the reorder threshold
An ingredient handling operation
Non-contact radar provides continuous level readings and a configurable low-level alert before inventory reaches 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 use reduced from 28.0 to 5.5 m³/day | Carlsberg Canada | Water | $38,400 per year |
| More than 450,000 litres saved in four months | 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 detected six weeks before failure | 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 alert before 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 |
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