Critical RTO Spare Parts Prevent Major Downtime
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An RTO failed during extreme cold, but critical spare parts kept onsite enabled fast repair and avoided costly production downtime. Learn how Kono Kogs helped.
Problem
During a period of extreme winter temperatures, a large printing and packaging manufacturer had their oxidizer suddenly fail. The root cause traced back to the compressed air system supplying the unit’s pneumatic valves and actuators.
Low temperatures compromised the desiccant dryer’s ability to remove moisture from the air stream. As moisture entered the control lines and subsequently froze, critical components could not actuate properly, preventing the oxidizer from functioning properly.
With the oxidizer offline, the facility faced the risk of haltered production, emissions non-compliance, and extended downtime – especially if replacement parts were delayed or on backorder.
Photos: In Progess
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Solution
The customer contacted Kono Kogs for immediate support. Because the customer purchased the complete spare parts package, we were able to notify the maintenance manager that the component was already on site. He quickly located it and completed the replacement himself, without needing support from our service team.
Photos: After
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Equipment & Services Provided
- Critical spare parts (desiccant dryer)
- Remote troubleshooting support (initial assessment)
Results
The oxidizer was able to return to service the same day, limiting total downtime to only one to two days.
By having a critical spare available, the customer:
- Avoided extended outages caused by parts backorders
- Maintained production schedules
- Preserved emissions compliance
- Restored reliable compressed air performance
- Reduced overall downtime risk during winter conditions
Moisture control issues in compressed air systems are a common cause of winter‑related oxidizer failures. In this case, having a critical spare desiccant dryer available allowed for a fast, cost‑effective recovery—and reinforced the value of a proactive spare parts strategy.
