Case Study: IFFCO avoids costly pump downtime with Nanoprecise Sci Corp’s predictive maintenance solution

Detection Of A Bearing Outer Race Failure On A Critical Pump Saved Downtime Cost Of $145k

Indian Farmers Fertiliser Cooperative (IFFCO), one of India’s largest fertilizer manufacturers, was facing repeated failures with a critical process condensate pump, which would break down every 6 to 12 months. Each unplanned outage cost up to $145,000 per day in lost production. IFFCO engaged Nanoprecise Sci Corp to implement its RotationLF predictive maintenance solution to detect faults early and predict equipment failure.

Nanoprecise installed its wireless RotationLF sensors to monitor the pump and motor bearings. Approximately one month after installation, the system detected an early-stage bearing outer race failure and alerted the plant staff. This early warning, which included a remaining useful life prediction of 37 days, allowed IFFCO to verify the fault and schedule a repair during a planned outage, avoiding costly unplanned downtime.

Indian Farmers Fertiliser Cooperative