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 plants, 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.
G5 — 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 (R2). G7 — clients are named only where permission exists; everywhere else a study is anonymized to its industry.
Two rails. Combine them.
Filter by what we measured, by the kind of plant, or by both at once.
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.
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 plant
A leaking cooling loop found and isolated with the line still running.
1 loopisolated
Illustrative scenario — representative of common industrial IoT applications
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 — representative of common industrial IoT applications
Compressed airManufacturing — automotive, plastics & rubberMetal Fabrication & Finishing
Compressed air leaks in a stamping operation
A Tier 2 automotive stamping plant
The most expensive utility per unit of work, leaking into an empty building overnight.
20–30%of compressor output
Illustrative scenario — representative of common industrial IoT applications
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 — representative of common industrial IoT applications
Cooling towersWaterManufacturing — automotive, plastics & rubberBuilding Materials & Heavy Industry
Cooling tower blowdown optimization
A plastics manufacturing plant
Blowdown running on a timer instead of on conductivity, discharging good water.
1 setpointchanged
Illustrative scenario — representative of common industrial IoT applications
Compressed airNatural gasMetal Fabrication & FinishingBuilding Materials & Heavy Industry
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 — representative of common industrial IoT applications
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 — representative of common industrial IoT applications
Natural gasBuilding Materials & Heavy IndustryManufacturing — automotive, plastics & rubber
A 1970s boiler brought onto the dashboard
A heavy manufacturing plant
A fifty-year-old boiler, integrated through its 4-20 mA output. Nothing was ripped out.
4-20 mAintegration
Illustrative scenario — representative of common industrial IoT applications
Energy & electricityManufacturing — automotive, plastics & rubber
Three plants, one unit of production, one outlier
A three-plant manufacturer
Same product, same equipment — one plant used about 40% more energy per unit.
~40%more energy per unit
Illustrative scenario — representative of common industrial IoT applications
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 — representative of common industrial IoT applications
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 — representative of common industrial IoT applications
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 — representative of common industrial IoT applications
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 — representative of common industrial IoT applications
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 — representative of common industrial IoT applications
WaterFood & Beverage Processing
Weekend ghost flow in an empty building
A food processing plant
Water still running through an empty plant all weekend — around a fifth of the monthly bill.
~20%of the monthly water bill
Illustrative scenario — representative of common industrial IoT applications
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 — representative of common industrial IoT applications
| 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 plant | 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 plant | 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 plant | 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 plant | Natural gas | 4-20 mA integration | Illustrative |
| Three plants, one unit of production, one outlier | A three-plant manufacturer | 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 plant | 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 on the study page (§H.1). An illustrative scenario carries no client, no logo and no measured figure.
Sparklines are drawn from each study’s own dataset — the same file its detail page charts. Representative sets are flagged provenance in src/data/widgets/ and are hot-swappable for the real sets (G6) with no markup change.
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