Two costs quietly drain most plants: the energy a line wastes, and the money it loses every hour it's stopped. Both are measurable. Below is the model we build with your real figures during a line review.
Two levers, one review
Energy cost is a product of four things you can influence. Efficiency work pushes on each one.
Right-sizing motors lowers the load. Variable-speed drives and sequencing lower the load factor and the hours. Better rates and metering keep the last two honest. Reduce any factor and the whole bill falls with it.
Take a single oversized 75 kW motor running 8,000 hours a year at $0.14/kWh:
…on that one motor's energy alone. That's the pool efficiency work draws from — before you count the rest of the line. Your line review replaces these placeholders with your meters, tariffs and runtimes.
Illustrative figures — not a quoted result
A halted line bleeds money in three directions at once. Reliable, safer equipment reduces both how often it stops and how long it stays down.
Lost output is units missed times their margin. Idle labour is the crew paid to wait. Restart cost is scrap, warm-up and lost momentum. Safety systems cut the incidents that trigger stoppages; recommissioning cuts the breakdowns that come from worn, obsolete equipment.
| Cost driver | What it captures |
|---|---|
| Lost output | Units not made × contribution margin |
| Idle labour | Crew paid while the line waits |
| Restart | Scrap, warm-up, lost momentum |
| Knock-on | Missed shipments and overtime to catch up |
We quantify each row against your line in the review
A full line replacement is the largest number on this page — and often the least necessary. Recommissioning restores reliable output for a fraction of that cost, and buys you the time to replace on your schedule rather than an emergency's. That's why we lead with it.
How recommissioning worksEvery figure on this page is illustrative. We make no claims about specific results until we've measured your line.