Wastewater

Predictive maintenance solutions for critical wastewater facility assets

Boiler Feed Water Pumps + -

Most industrial pumps operate at less than half of their potential efficiency, usually due to poor operating conditions and practices that can be impossible to pinpoint with traditional approaches to maintenance.

Pumps consume 25% of all industrial energy
Pumps typically operate at 40% efficiency
Inefficiency costs $500,000 on average over the pump’s lifespan

Motors and pumps with large pipes in a utilities plant.

Cooling Towers + -

Cooling towers are hard to reach and hard to monitor, so many maintenance pros miss key indicators of imminent failure. Tower failure can have downstream impacts on almost all production processes.

$1,000/hour downtime cost
$50,000 in equipment costs per failure
$100,000+ cost savings per avoided failure

Induced/Forced Draft Fans + -

Route-based maintenance doesn’t capture the full picture of ID/FD fan health. These fans are large, putting relatively small data anomalies lower on the priority list — but they are often a warning sign of imminent failure.

Up to $20,000/hour downtime cost
$250,000 in equipment costs per failure
$300,000+ cost savings per avoided failure

"We've literally paid for three years of service in five months."

Jon Driscoll, Information Technology Coordinator
Altoona Water

Customer Success Story

"By deploying sensors and optimizing the strategy, they reduced this cost to about $1.8 million, saving roughly $900,000 over three years."

Thom Brotski, CEO
Harrison Group LLC

Customer Success Story

"We're saving our employees from having to enter potentially dangerous situations."

Jon Driscoll, Information Technology Coordinator
Altoona Water

Customer Success Story

"We're getting a lot more catches because the guys aren't having to diagnose it. It's telling them. We're much more responsive and we're getting four times as many catches as we used to."

Mark Rosen, President U.S. Division
Calfrac Well Services

Customer Success Story

Case Study Spotlight

Altoona Water Authority

Safeguarding communities through efficient wastewater management.

On December 13th, a significant spike in peak acceleration and velocity readings at Altoona Water Authority, a public wastewater facility in Altoona, PA, caught the attention of SMARTdiagnostics. Thanks to the rapid response from SENTRYsolutions, plant operators were prompted to inspect the dryer motor and potentially grease the inboard bearing.

Read Case Study

Industrial wastewater plant shown from above with drone footage.

Wastewater treatment highlight

Municipal Utility District, Katy Texas & KCF Technologies

Pumps, motors, and blowers are the backbone of municipal wastewater systems, but when they fail, the impact is immediate. In Katey, Texas, KCF Technologies helped transform raw machine data into proactive insights that extended asset life, reduced downtime, and improved overall plant efficiency.

Discover how this team went from reactive fixes to predictive wins—using real-time diagnostics and strategic guidance to boost system reliability and safeguard community infrastructure.

View Case Study

Related case studies

Linear Motion Mixers

Optimizing Linear Motion Mixers: Altoona Water’s Predictive Approach

Altoona Water caught a critical issue early with KCF SMARTdiagnostics. Insights from the $199 pilot is now being deployed to fix all their Linear Motion Mixers.

View Case Study

Vacuum Pump

Vacuum Pumps

Vacuum pumps are critical in many manufacturing processes. KCF's comprehensive machine health monitoring empowers you with the data and insights needed to minimizing unplanned downtime.

View Case Study

Keystone Clearwater Solutions

Explore the partnership between Keystone Clearwater Solutions and KCF Technologies, providing machine health monitoring for 100% of their critical pumps and motors.

View Case Study

$ 4 Billion+

in customer savings

85,000

hours of downtime prevented

1.2 Billion

data points per month

Request a demo

Want to eliminate unplanned downtime and extend the lifespan of your critical assets?
Contact us to see how our comprehensive, AI-driven machine health platform can optimize your operations.

Book Demo

Trusted by leading wastewater facilities

Predictive maintenance solutions for critical wastewater facility assets

Gain a competitive edge with KCF

Altoona Water Authority

Municipal Utility District, Katy Texas & KCF Technologies

Related case studies

Why KCF

Request a demo