Case studies
What we found, what it cost, and what changed.
Water, energy, compressed air, predictive maintenance, temperature and humidity, silo levels, natural gas and cooling towers — in Canadian factories, on real meters.
Every study below runs the same way: the alert nobody was watching for, what it was costing, the fix, and the meter afterwards. The chart on each one is the chart we were looking at.
There are two things worth reading these for. One is the money — the leak, the compressor, the overnight load, the fix and what it was worth. The other is harder to put on an invoice and is often what the factory ends up leaning on: production visibility. Product temperature through a process. Vibration on a bearing weeks before it lets go. Humidity in a curing room, level in a silo at 3 a.m. Numbers a factory has never had, on things it has always cared about.
Interested in one of these? We’d be happy to connect you with the people at that factory.
The 3 named studies are real client results and print their sources. Everything else is an illustrative scenario, ribboned as one, and is never presented as a client result. Clients are named only where permission exists; everywhere else a study is anonymized to its industry. G5 · R2 · G7.
Two rails. Combine them.
Filter by what we measured, by the kind of factory, or by both at once.
Industry9
Showing 19 of 19 case studies
Every single-rail state is a real page with its own address, so a filtered view can be linked, bookmarked and found in search. The combined state lives in the URL as a parameter.
19 case studies
Real results first. Every card carries the headline number and the shape of the data behind it — the card is the study, so there is nothing else to click through to.
No case study matches that combination yet. to see all 19.
Predictive maintenanceWaterBreweries & Beverage
A failing diaphragm pump, caught before it failed
Carlsberg Canada
A failing diaphragm pump caught before it failed — 540,000 L/day of loss prevented.
540,000 Lper day
WaterBreweries & BeverageFood & Beverage Processing
Pasteurizer water down from 28.0 to 5.5 m³/day
Carlsberg Canada
Pasteurizer water down from 28.0 to 5.5 m³/day — $38,400/yr, no capital cost.
$38,400per year
Compressed airWaterFood & Beverage ProcessingBulk Handling & Rail Logistics
Over 450,000 litres saved in four months — and the clearest compressor graph we've produced
PDI Bulk
>450,000 litres of water saved in four months, and the clearest before/after compressor graph we've ever produced.
>450,000 Lin 4 months
WaterManufacturing — automotive, plastics & rubber
Chiller circuit leak isolated without a shutdown
An automotive factory
A leaking cooling loop found and isolated with the line still running.
1 loopisolated
Illustrative scenario
Temperature & humidityFood & Beverage ProcessingControlled Environment Agriculture
A cold-storage alert at two in the morning
A cold storage operation
A refrigeration fault caught overnight, before the product was.
2 a.m.alert
Illustrative scenario
Compressed airManufacturing — automotive, plastics & rubberMetal Fabrication & Finishing
Compressed air leaks in a stamping operation
A Tier 2 automotive stamping factory
The most expensive utility per unit of work, leaking into an empty building overnight.
20–30%of compressor output
Illustrative scenario
Predictive maintenanceBulk Handling & Rail LogisticsManufacturing — automotive, plastics & rubber
Conveyor drive bearing degradation caught six weeks early
A bulk handling facility
A bearing changed its signature about six weeks before it would have seized.
6 weeksof warning
Illustrative scenario
Cooling towersWaterManufacturing — automotive, plastics & rubberBuilding Materials, Concrete & Aggregates
Cooling tower blowdown optimization
A plastics manufacturing factory
Blowdown running on a timer instead of on conductivity, discharging good water.
1 setpointchanged
Illustrative scenario
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
Illustrative scenario
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
Illustrative scenario
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
Illustrative scenario
Energy & electricityManufacturing — automotive, plastics & rubber
Three factories, one unit of production, one outlier
A manufacturer with three factories
Same product, same equipment — one factory used about 40% more energy per unit.
~40%more energy per unit
Illustrative scenario
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
Illustrative scenario
Cooling towersEnergy & electricityFood & Beverage ProcessingControlled Environment Agriculture
Refrigeration condenser fouling detection
A food storage and processing site
Rising head pressure at constant load — a fouled condenser, priced.
Head pressurevs. load
Illustrative scenario
Silo & levelFood & Beverage ProcessingControlled Environment Agriculture
Silo level early warning at the reorder threshold
An ingredient handling operation
Non-contact radar level, continuous, with a low-level alert before the reorder deadline.
0silo climbs
Illustrative scenario
Natural gasPharmaceutical & ChemicalFood & Beverage Processing
Steam trap failure monitoring
A pharmaceutical manufacturing site
A failed-open steam trap vents energy continuously and silently.
Continuousmonitoring
Illustrative scenario
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
Illustrative scenario
WaterFood & Beverage Processing
Weekend ghost flow in an empty building
A food processing factory
Water still running through an empty factory all weekend — around a fifth of the monthly bill.
~20%of the monthly water bill
Illustrative scenario
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
Illustrative scenario
| A failing diaphragm pump, caught before it failed | Carlsberg Canada | Predictive maintenance, Water | 540,000 L per day | Real result |
| Pasteurizer water down from 28.0 to 5.5 m³/day | Carlsberg Canada | Water | $38,400 per year | Real result |
| Over 450,000 litres saved in four months — and the clearest compressor graph we've produced | PDI Bulk | Compressed air, Water | >450,000 L in 4 months | Real result |
| Chiller circuit leak isolated without a shutdown | An automotive factory | Water | 1 loop isolated | Illustrative |
| A cold-storage alert at two in the morning | A cold storage operation | Temperature & humidity | 2 a.m. alert | Illustrative |
| Compressed air leaks in a stamping operation | A Tier 2 automotive stamping factory | Compressed air | 20–30% of compressor output | Illustrative |
| Conveyor drive bearing degradation caught six weeks early | A bulk handling facility | Predictive maintenance | 6 weeks of warning | Illustrative |
| Cooling tower blowdown optimization | A plastics manufacturing factory | Cooling towers, Water | 1 setpoint changed | Illustrative |
| 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 | Illustrative |
| Night setback that never happened | A distribution warehouse | Energy & electricity | ~35% of overnight electrical load | Illustrative |
| A 1970s boiler brought onto the dashboard | A heavy manufacturing factory | Natural gas | 4-20 mA integration | Illustrative |
| Three factories, one unit of production, one outlier | A manufacturer with three factories | Energy & electricity | ~40% more energy per unit | Illustrative |
| Pump cavitation caught three weeks early | A municipal water facility | Predictive maintenance | 3 weeks of warning | Illustrative |
| Refrigeration condenser fouling detection | A food storage and processing site | Cooling towers, Energy & electricity | Head pressure vs. load | Illustrative |
| Silo level early warning at the reorder threshold | An ingredient handling operation | Silo & level | 0 silo climbs | Illustrative |
| Steam trap failure monitoring | A pharmaceutical manufacturing site | Natural gas | Continuous monitoring | Illustrative |
| Tank level and inventory reconciliation | A bulk chemical storage operation | Silo & level | Continuous reconciliation | Illustrative |
| Weekend ghost flow in an empty building | A food processing factory | Water | ~20% of the monthly water bill | Illustrative |
| Welding bay CO and CO₂ monitoring | A metal fabrication shop | Temperature & humidity | Continuous vs. quarterly | Illustrative |
Real results carry their source. An illustrative scenario carries no client, no logo and no measured figure.
Sparklines are drawn from each study’s own dataset. The per-study pages are not linked for this launch — ask us and we will walk you through any of these, or put you in touch with the factory. Representative sets are flagged provenance in src/data/widgets/ and are hot-swappable for the real sets (G6) with no markup change. §C: the detail pages are unlinked for the v3 launch pending their redesign.
Common questions
Before you read nineteen of these.
Are these real client results?
Some are and some are not, and the page says which on every card. 3 of the 19 studies below are measured results from named or anonymized Canadian clients, and each one prints its source. The rest are marked "illustrative scenario" — representative of common industrial IoT applications, built from the same charting system, never presented as something that happened at a client. If a card carries no illustrative stamp, the numbers on it came off a meter.
Can we talk to the factory in one of these case studies?
Usually, yes. If one of these is close to your situation, tell us which and we will ask the client whether they are willing to take a call. Most say yes, because the people running these factories were sceptical once too. It is a better use of an hour than reading another page about it, and there is nothing we would tell you that they will not.
What besides cost savings does this actually give a factory?
Production visibility. Cost reduction is the half that is easy to put in a spreadsheet, but the numbers most clients end up leaning on are the ones they never had at all: product temperature through a process, vibration on a bearing weeks before it fails, humidity in a curing room, level in a silo at three in the morning. Those readings change how the factory is run, not just what it spends.
How long before a project produces a number like these?
The first surprise usually shows up within a week of the sensors going live, and it is almost always overnight or weekend consumption on something everybody believed was switched off. Turning that into a defensible annual figure takes a full billing cycle or two, because the honest way to state a saving is to show the meter before and the meter after with the same conditions on both sides.
Additive per aeo-playbook.md §4b. The FAQPage JSON-LD mirrors this copy exactly.
Your factory is next.
Thirty minutes, your utility bills, and an honest read on what is worth metering first. If we don’t think a project will pay for itself, we’ll tell you that too — it’s a short conversation either way.
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