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Case Study 4

 

Emergency Service Callout & PPM Recovery for Recycling Plant Control Room

 

Client: Confidential recycling and waste management client

Sector: Industrial / Recycling & Waste Management

Services Delivered: Service, Maintenance & Emergency Callout · Air-conditioning · Planned Preventative Maintenance (PPM

 

Project Overview:

Tailored Air Limited was called to attend an emergency service visit at a recycling plant where all air-conditioning systems had originally been installed by Tailored Air two years prior. Following installation, a planned preventative maintenance (PPM) contract had been offered but was not taken up by the client.

After operating for two years without a maintenance regime, the site experienced a critical system failure during a period of exceptionally warm weather. The resulting loss of cooling to the recycling plant control room brought plant operations to a halt, directly impacting productivity and revenue.

 

Condition on Arrival:

  • Upon arrival on site, Tailored Air engineers identified multiple critical issues caused by the lack of routine maintenance:

  • All four condenser coils were fully blocked, severely restricting heat rejection.

  • All indoor unit filters were blocked, significantly reducing airflow and system performance.

  • One compressor had failed due to prolonged system strain.

  • One inverter control board had failed, further compromising system operation.

  • Loss of cooling within the control room resulted in the recycling plant being unable to operate.

 

Key Challenges:

  • The service callout presented several immediate challenges:

  • Critical downtime: Loss of cooling had stopped plant operations, creating urgent commercial pressure.

  • Severe system contamination: Blocked coils and filters required intensive cleaning to restore airflow.

  • High ambient conditions: Works were carried out during an exceptionally warm period, increasing system demand.

  • Balancing recovery and repair: Temporary operational recovery was required while planning permanent repairs.

 

Tailored Air Solution:

  • Tailored Air engineers responded quickly to minimise downtime and stabilise the system.

  • Rapid site attendance: Engineers attended site promptly following the callout.

  • Deep cleaning works: Three intensive deep cleans were carried out to condenser coils and internal components.

  • System recovery: Air-conditioning was restored to approximately 75% operational capacity, allowing the control room to resume operation.

  • Planned repairs: Replacement of the failed compressor and inverter board were scheduled as follow-on works.

  • Clear communication: The client was kept fully informed throughout, with transparent reporting on system condition and next steps.

 

Results:

Control room cooling reinstated, allowing recycling plant operations to resume

Immediate reduction in operational downtime and revenue loss

System stabilised during extreme weather conditions

Permanent repair works scheduled to fully restore system performance

PPM contract secured following service intervention

 

Outcome & Value:

This project clearly demonstrates the critical importance of a structured planned preventative maintenance regime. Without regular servicing, system efficiency deteriorates, component failure risk increases and unplanned downtime becomes inevitable.

By contrast, a PPM regime ensures clean heat exchangers, unrestricted airflow, early fault detection and prolonged equipment life—dramatically reducing the risk of catastrophic failure and costly business interruption.

Following Tailored Air’s rapid response and transparent reporting, the client now benefits from an ongoing PPM contract, protecting their investment and ensuring reliable operation moving forward.

 

About Tailored Air Limited:

Tailored Air Limited specialises in the installation, service and maintenance of air-conditioning and ventilation systems across commercial, education, public sector and hospitality environments. Known for quality workmanship, strong coordination and reliable delivery, Tailored Air supports clients from installation through to long-term maintenance.

 

For more information or to discuss similar projects, contact Tailored Air Limited.

 

 

 

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