Case Study: a chemical manufacturer predicts equipment failures and avoids downtime with Falkonry AI

How Falkonry helped anticipate failures and avoid downtime

The chemical manufacturer faced challenges with unexpected equipment failures, particularly with gas compressor valves and seals and centrifuge plugging, which caused costly unscheduled downtime and repairs exceeding $285,000 annually. Routine inspections and conventional monitoring methods provided insufficient warning, only detecting issues when failure was imminent. To address this, they partnered with Falkonry to implement its AI-powered analytics service.

Falkonry's AI analyzed process and condition data to learn the patterns preceding equipment failure. This solution enabled the customer to detect centrifugal failures 10 days in advance, allowing maintenance to be planned for scheduled periods. Furthermore, process engineers identified the root causes of premature failure, enabling process adjustments to improve overall reliability and avoid costly downtime.