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By Mr. Satish Ingavale, MD, John Crane India

Industries worldwide are experiencing growing pressure to increase their output while optimising resource consumption. Production targets are rising, but so are the prices of inputs such as energy, driven by ongoing supply chain disruptions. These circumstances have intensified conversations about improving the reliability and operational efficiency of plant equipment.

Equipment, such as pumps, compressors, and turbines, is becoming central to meeting industrial targets without compromising cost or sustainability. As a result, companies are taking a closer look at how their rotating equipment is run and maintained not as an afterthought, but as a strategic priority that directly affects performance on the ground.

Reliability: A Strategic Necessity, not a Maintenance Task

As supply chains tighten and delivery timelines shrink, even a brief disruption can lead to significant losses, especially in industries such as oil and gas, power generation, chemical processing, and water treatment, where uptime is critical. When a pump stops functioning or a compressor shuts down, the effects are felt across the production line. Estimates suggest that in the oil and gas sector, a single hour of downtime can cost anywhere from USD 100,000 to USD 1 million, depending on the equipment involved. These incidents reflect broader challenges in how essential machinery is monitored, maintained, and prioritised.

Ensuring reliability is no longer optional; it is a strategic necessity. Equipment that runs consistently brings stability to operations, reducing unplanned outages, last-minute fixes and costly delays.

Efficiency That Goes Beyond Energy Savings

Rotating equipment is one of the largest consumers of energy in industrial operations. According to the International Energy Agency (IEA), electric motors and motor systems, including pumps, fans and compressors, account for nearly 53% of global electricity use in industry and infrastructure applications.

When these systems are not functioning at peak efficiency, energy loss can increase dramatically. Malfunctioning equipment not only wastes power but also generates excess heat and noise, accelerates wear and increases maintenance frequency.

In contrast, equipment operating at optimal performance consumes less power, produces fewer emissions, and enjoys a longer service life. This supports both financial outcomes and broader environmental goals. Companies that invest early in performance optimisation often recover costs through extended maintenance intervals, reduced downtime and improved consistency.

Achieving this level of efficiency, however, depends on having real-time visibility into how machines are performing.

Smarter Monitoring Is Changing How Plants Operate

The shift from reactive to proactive maintenance isn’t new, but the tools enabling it have evolved rapidly. Today’s monitoring systems track a wide range of parameters in real time, including vibration, temperature, pressure fluctuations and fluid condition.

This continuous stream of data helps identify small, subtle behaviour changes – early signs of imbalance, bearing wear, or flow obstruction before a failure occurs. With this insight, operators can plan interventions around production schedules instead of interrupting operations for unplanned repairs.

Precision Repairs Unlocking Long-Term Performance

Even with the best maintenance, mechanical parts wear over time. Bearings degrade, seals fail, and alignment shift. While full replacement may sometimes be necessary,  many systems can be restored to original performance through high-precision repairs.

The key lies in how those repairs are carried out. A quick fix may restart the machine, but unresolved misalignments or minor defects can create stress on connected components, leading to further failures.

Repairs done using calibrated tools, standardised procedures, and thorough testing can significantly extend equipment life. Some companies also incorporate small upgrades, such as switching to modernised couplings or advanced materials during refurbishment, allowing legacy systems to meet modern demands without requiring full-scale replacement.

Everyone Has a Role in Equipment Health

Reliability and efficiency shouldn’t rest solely with the maintenance team. Procurement, engineering, operations and finance all influence how equipment is selected, operated and maintained. Disconnected decision-making, often driven by short-term cost goals, can limit long-term performance.

A shared approach begins with awareness. Cross-functional teams need to understand how their choices affect equipment behaviour and performance outcomes. Training, open communication and access to performance data help build that understanding. When all functions work toward common goals, reliability becomes part of the operational culture rather than a reactive task.

Smarter Machines for a More Demanding Tomorrow

As industries become more digitised and connected, the monitoring, maintenance and upgrading of rotating equipment are becoming easier and more effective. Real-time data is enabling predictive maintenance, remote diagnostics and smarter asset management.

Meanwhile, tightening environmental regulations and closer scrutiny of energy usage are driving companies to reconsider equipment performance as a competitive differentiator.

Organisations that run equipment reliably and efficiently benefit from smoother operations, reduced costs, and greater agility. It also positions organisations to respond more quickly to shifts in demand or production strategy. In a landscape where resilience and responsiveness are key, the ability to trust in every asset makes a measurable difference.

Conclusion

Rotating equipment may not always be the most visible part of industrial infrastructure, but its performance sets the tone for everything else. Reliable machines reduce risk and efficient equipment lowers cost. Together, they build a foundation for sustainable growth.  

Organisations that prioritise these outcomes are better equipped to respond to policy changes, expand production and meet their sustainability targets. The path forward begins with equipment that performs as hard as the business it powers.