March 11, 2026
In fertilizer plants, grain terminals, and material handling facilities, unplanned downtime is one of the most expensive risks operators face. A single equipment failure can halt production, delay shipments, and erode margins. Preventive maintenance shifts facilities away from reactive firefighting toward planned, strategic reliability.
The Real Costs of Downtime
Unplanned outages are not rare events. 82 percent of industrial companies report at least one in the past three years. Research from ABB shows unplanned downtime can cost US $125,000 per hour on average, with some manufacturing outages reaching US $260,000 per hour. In Canada, the number is even higher: CAD $242,000 per hour for facilities that experience outages on a monthly basis.
These costs extend far beyond immediate repairs. Every unscheduled shutdown carries secondary consequences: overtime labour, rush shipping of parts, penalties for missed delivery schedules, and the reputational damage that lingers long after operations resume.
“When the weather shifts from cold to warm or back again, that’s when belts are at the highest risk. Catching those tracking issues before they escalate avoids burnt belts and lost production,” says Tim Robertson, Director of Operations, Cleaner Division, KPIC.
Planned Work vs. Emergency Work
Planned maintenance allows operators to schedule interventions during low-impact windows. Parts can be ordered in advance, crews prepared, and downtime kept to a minimum. Emergency failures, by contrast, force procurement into rush shipping, inflate costs with premium labour, and often trigger a cascade of secondary breakdowns. Industry data shows emergency repairs can cost three to ten times more than planned work.
“Downtime is when our clients lose the most. That’s why we stage common bearings, couplings, and filters before a shutdown even begins,” says Dana Bell, Procurement Manager, KPIC.
Extending Asset Lifespan and Improving Safety
Every piece of industrial equipment represents a major capital investment. Preventive maintenance extends the lifespan of conveyors, cleaners, motors, and structural systems by ensuring they are serviced before failure. Bearings that are lubricated on time can run years longer. Motors with clean airflow avoid overheating and burnout. Cracks in welds, caught early, prevent costly and dangerous failures.
Safety is just as important as efficiency. A seized pulley or broken coupling can create hazards that threaten workers. Preventive programs reduce the probability of these failures, protecting both people and production.
“For us, safety and reliability are tied together. A disciplined preventive routine means fewer surprises and a safer site for everyone involved,” says Jay Fehr, Regional Manager, KPIC.
Continuous Improvement
Preventive maintenance is not static. Every inspection, repair, and shutdown adds to a feedback loop that helps facilities get smarter over time. By documenting patterns in equipment wear, teams can refine intervals, adjust task lists, and focus on the issues that matter most. Over time, this reduces waste, increases reliability, and strengthens a facility’s competitive position.
The KPIC Approach
At KPIC, preventive maintenance is not a one-size-fits-all checklist. It is tailored to each facility’s production cycle and equipment profile. Our field crews work with procurement to ensure the right parts are staged in advance. Our inspections are structured around seasonal surges and operational priorities, with safety built into every step.
From fertilizer plants preparing for spring to grain terminals that cannot afford an hour of downtime, our goal is straightforward: keep operations running safely, efficiently, and profitably.
