A large food processing facility in the Midwest relied on a network of high-speed pumps, motors, and gearboxes to keep production lines moving 24/7. Despite routine maintenance, the plant struggled with recurring failures, pumps were breaking down every few months, seals wore out prematurely, and energy bills kept climbing. Traditional alignment methods, including straightedges and dial indicators, were still in use, but results were inconsistent and difficult to verify.
Technicians discovered that even small coupling misalignments were having outsized effects. For example, a mere .015” gap at 3,000 RPM increased power consumption by nearly 4% per motor. Across dozens of machines, this translated into thousands of dollars in wasted electricity each year. At the same time, seals and bearings were failing at three to four times their expected lifespan, causing costly downtime during peak production runs.
The facility invested in Hamar Laser’s X-Series™ Laser Shaft Alignment System, moving away from outdated manual methods. The X-Series was chosen for its:
20X measurement resolution, detecting misalignment down to sub-micron accuracy.
60–70% faster alignments, cutting alignment time from hours to under an hour.
Easy-Guide™ software, which walked technicians through the process step-by-step, reducing training needs.
Live Move Data, allowing mechanics to see corrections in real time.
Professional reporting, creating compliance-ready documentation for maintenance audits.
Maintenance costs
Down 6%
Energy usage
Decreased by
8%
Machine availability
increased by
10%
Seal life increased
Up to 8x
Coupling life
Significantly
extended
reducing costs
Within the first six months of implementation, the plant saw dramatic improvements:
Maintenance costs dropped by 6%, as bearing and seal replacements declined.
Energy usage decreased by 8%, verified through lower amp draw on aligned equipment.
Machine availability improved by 10%, reducing unplanned downtime.
Seal life increased up to 8x, extending from 3 months to over 2 years in some units.
Coupling life was significantly extended, reducing costly replacements.
By switching from dial indicators to laser alignment, the facility not only eliminated recurring pump failures but also improved efficiency across its entire operation. The combination of higher accuracy, faster alignments, and automated reporting made the investment pay for itself in less than a year.
Comparison of key performance metrics before and after implementing X-Series™ Laser Alignment
| Metric | Before X-Series™ | After X-Series™ | Improvement |
|---|---|---|---|
| Maintenance Costs | High | Reduced | 6% |
| Energy Usage | High | Reduced | 8% |
| Machine Availability | Baseline | Improved | 10% |
| Seal Life | 3 months | 2+ years | 8x longer |
| Coupling Life | Frequent fails | Extended | Significant |
Assumptions for this example: You have a 480 volt motor drawing 40 amps and operating 8400 hours/year. The Power Factor is .85. Electricity costs $0.06/kWhr. Also assume that the amp draw is measured before and after the alignment and it is found that there is a 1 amp difference.
kW =V* A*PF*1.732/1000
kW =480V* 1A*.85*1.732/1000
kW =.706 = power savings
Savings ($) = operating hours * kW savings * kW cost
Savings ($) = 8400 * .706 * $0.06/kWhr
Savings ($) = 8400 * .706 * $0.06/kWhr
Savings ($) = 355.82
If your plant has 80 similar motors, and if only half of them had the same amount of savings, it would total $355.82 * .5 = $14,232!
The coupling icons next to the data displays show the direction of the misalignment at the coupling and update as you move or shim the motor! You can also zoom in on the coupling to show them in the live display area of the screen.
