Proven Results
Real Plants. Real Savings.
Every engagement we take on is backed by a commitment to measurable, documented results. Here is a sample of what our clients have achieved.
Pulp & PaperGreenfield Paper Mill Reduces Bearing Failures by 74%
Upstate South Carolina
Food & BeverageFood Processing Facility Cuts Steam Loss by 60%
Charlotte, North Carolina
Steel ManufacturingSteel Plant Achieves 22% Energy Reduction via Compressed Air Audit
Spartanburg, South Carolina
Pulp & PaperGreenfield Paper Mill Reduces Bearing Failures by 74%
The Challenge
A large pulp and paper mill was experiencing frequent unplanned bearing failures on critical rotating equipment, resulting in an average of 3–4 unplanned shutdowns per quarter. The facility had no formal lubrication program and technicians were re-greasing on an ad-hoc basis with no standardized products or quantities.
Our Solution
Newton Industrial Solutions conducted a full plant lubrication survey identifying 47 critical lubrication points lacking standardized procedures. We developed a precision greasing program, consolidated the lubricant inventory from 18 products to 6, created documented route sheets for all lube technicians, and delivered onsite training to the maintenance team.
Results
- 74% reduction in lubrication-related bearing failures
- $280,000 in annual maintenance cost savings
- Bearing MTBF extended from 14 months to 38 months
- Lubricant inventory cost reduced by 34%
- Technician certification program launched for 8 team members
Food & BeverageFood Processing Facility Cuts Steam Loss by 60%
The Challenge
A food and beverage manufacturing facility in Charlotte was paying above-market steam generation costs with no visibility into system losses. A preliminary energy audit suggested significant steam trap failures, but the plant had never conducted a comprehensive survey.
Our Solution
Newton conducted a full steam trap survey across 214 traps in the facility. Using ultrasonic testing, we identified 87 failed or failing traps, quantified the energy losses per trap, and delivered a prioritized repair schedule based on annual loss value. We also implemented a steam trap management program for ongoing monitoring.
Results
- 60% reduction in steam system energy losses
- $142,000 recovered in annual energy costs
- 87 failed traps identified and prioritized for repair
- Steam trap management program implemented
- Annual re-inspection schedule established
Steel ManufacturingSteel Plant Achieves 22% Energy Reduction via Compressed Air Audit
The Challenge
A steel manufacturing facility was experiencing unexplained spikes in compressed air system energy consumption. The plant had 3 large air compressors running at near-full capacity despite no changes in production volume. Management suspected significant system leakage but lacked the data to justify capital investment in repairs.
Our Solution
Newton performed a comprehensive compressed air leak survey using acoustic ultrasonic detection equipment, surveying all headers, drops, distribution lines, and end-use connections. We identified 143 leaks across the facility, quantified each by estimated flow rate and annual cost, and delivered a prioritized repair report with ROI calculations.
Results
- 143 leaks identified across the compressed air system
- 22% reduction in compressed air energy costs
- One of three compressors taken offline after leak repairs
- $96,000 in annual energy cost savings
- Leak prevention program established with quarterly audits
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Your Plant Could Be Next
These results are not anomalies — they are what happens when certified lubrication expertise meets focused execution. Let us show you what is possible at your facility.