Case Study: Profertil achieves 80% cut in maintenance costs and $0.9M savings with GE Digital's Asset Answers (APM)

Profertil Cuts Production Losses, Bad Actor Monthly Maintenance Costs By 80%

Profertil, an Argentine petrochemical company that produces nitrogen fertilizers, identified its 02-F-201 primary ammonia reformer as its top “bad actor” after chronic tube failures and roughly $3.2M in maintenance costs between 2008–2010. The company invested $8M in an improvement project but lacked a tool to measure asset performance, quantify production losses, or calculate expected ROI.

To address this, Profertil deployed Asset Answers within GE Digital’s Machine & Equipment Health (Asset Performance Management) suite to benchmark assets and track KPIs. GE Digital’s solution analyzed historical work-order data, forecasting payback in under a year and revealing average monthly maintenance of $27K and production losses of $1.8M; after improvements Profertil saved about $0.9MM, cut monthly maintenance from $27K to $5K, and realized ROI in less than one year.

Profertil