Reliability Simplified Ethanol plants
Reliability support for dry mill ethanol plants: criticality, bad actors, PM strategy, critical spares and CMMS data, done with your crew and priced for a plant with one maintenance manager and no reliability engineer.
Plants that run hard with a small crew.
Most ethanol plants run year round with a lean maintenance crew, one maintenance manager, and no reliability engineer on staff. Fermentation does not wait, the dryers set the pace, and every unplanned stop is gallons that do not come back.
The reliability programs written for refineries and chemical complexes assume staff you do not have. Ours start from the crew you have today, one process area at a time, and leave the plant with records it can keep up on its own.
The work concentrates where ethanol plants lose their month: grind and hammer mills, fermentation and beer well pumps, centrifuges, evaporators, DDGS dryers, boilers and the thermal oxidizer. We also bring the register, the PMs and the spares list into a CMMS your planner will actually use.
Register, criticality, bad actors, PMs, spares.
Every item is done hands-on with your team and scoped to your plant. Nothing here is a software license.
- ✓ Asset register and CMMS data build
- ✓ Criticality ranking, RS 7-factor model
- ✓ Bad actor analysis from your work order history
- ✓ PM strategy built from failure modes
- ✓ Critical spares justification
- ✓ Centrifuge, pump and dryer reliability
- ✓ Shutdown planning and readiness
- ✓ Operator rounds and basic care
Two ways to start.
Site assessment
Fixed price · $5,600 · travel includedWe come to the plant, walk it, review your CMMS and failure history, and talk to the people doing the work. You get a scored report on where your program sits, the gaps that matter, and what to fix first.
Book the assessment →Reliability Support Plan
One flat monthly rate for a block of reliability hours, sized like a part-time engineer. The hours go where the need is that month: a criticality ranking, a bad actor review, a PM rewrite, a spares call, a problem on the floor. Run out, and you add hours at your tier rate or step up a tier for a lower rate. Month to month, or 3, 6 and 12 month terms. Ask us about it today.
Ask us about the planStraight answers.
We do not have a reliability engineer. Does this work without one?
Yes. It is built for that. The monthly program covers the reliability engineer function with a block of hours each month that goes where the need is, for a fraction of a hire, and the records stay with the plant.
Our CMMS data is thin. Can you still find the bad actors?
Yes. We start from the work orders you do have, parts purchases, and what the crew remembers, one process area at a time. The register gets built as we go, so the data problem is fixed while the analysis is done.
Do you have to be on site?
The assessment is on site. Most monthly program work is done remotely with site visits when the work needs eyes on the equipment. Plants in the same region are visited together to keep travel down.
What does a criticality ranking cost?
Inside the monthly program, a criticality ranking for one process unit fits in a month or two of your hours. Stand-alone, we scope it by unit count and quote it before we start.
Can you help with our fall or spring shutdown?
Yes. We run shutdown readiness across six phases and five gates, from scope freeze through startup, and we can plan and manage the event or review your plan and tell you where it is thin.
Where do you work?
We are based in Anacortes, Washington and work with plants worldwide. Most ethanol work is in the corn belt, and we cluster site visits by region.
Start with an assessment.
Tell us about your plant and what is failing. We will tell you where to start, and the assessment is one fixed price, travel included.