Industry News & Updates

Every summer, many factories and manufacturing plants shut down for planned maintenance or seasonal breaks. But when it is time to restart, machines do not always come back online smoothly. After sitting idle, critical equipment can suddenly show problems such as seized components, electrical faults, or complete breakdowns.

These unexpected failures can lead to expensive downtime, lost production, and missed delivery schedules. The good news is that most machinery failures after shutdown are preventable with the right approach. In this article, we will explore the most common reasons machines fail after shutdown and share practical ways to avoid costly breakdowns.

The Main Failure Points

Corrosion, Seizure and Mechanical Issues

Idle machinery is highly vulnerable to corrosion and seizure. When lubricants degrade and metal surfaces are left unprotected, moving parts can stick or seize completely. Restarting under these conditions puts immense strain on equipment and often results in catastrophic mechanical failure. This type of failure is one of the leading causes of unexpected industrial downtime after a shutdown.

Lubrication Problems

Lubrication is essential for smooth equipment performance. During a shutdown, grease and oil may settle, evaporate, or lose their protective qualities. Without proper lubrication, machines are exposed to overheating, excess friction, and premature wear. This increases the risk of costly breakdowns just when production needs to restart at full speed.

Electrical and PLC Faults

Electrical systems and PLCs (Programmable Logic Controllers) are another common failure point after shutdown. Power surges, wiring faults, or memory glitches can appear suddenly once systems are restarted. These faults can cause production lines to stop unexpectedly and, in some cases, even pose safety hazards to workers. Preventive inspection of electrical systems is essential before powering up again.

Dust, Environment and Contaminants

Shutdowns often expose machinery to environmental risks. Dust, moisture, and temperature fluctuations can accumulate in sensitive components during idle periods. When machines are restarted, these contaminants can cause short circuits, clogged filters, or insulation breakdown. Even small amounts of dust or moisture can significantly impact the reliability of industrial automation equipment.

Lack of Preventive Maintenance or Poor Planning

Many shutdown failures are the result of skipped preventive maintenance. When shutdowns and restarts are rushed, critical inspections and checks are often overlooked. A simple checklist could prevent many of these failures, yet without proper planning, small issues escalate into major breakdowns. Regular preventive maintenance remains one of the most cost-effective ways to protect equipment.

Supply Chain and Spare Parts Delays

Even with preparation, unplanned failures can still occur. The real challenge comes when replacement parts are not readily available. Critical automation components are often subject to long lead times or may even be obsolete. Every hour of downtime adds to production losses, making supply chain delays extremely costly. This is why stocking critical spare parts in advance is vital.

What This Means for Manufacturers

For manufacturers, restart risks highlight the importance of preparation. A single failed sensor, bearing, or capacitor might seem small, but when it halts an entire production line, the financial losses can be massive. Downtime costs can quickly exceed the cost of preventive maintenance or spare parts. Proactive planning is always more cost effective than scrambling to recover after machinery failure.

How to Prevent Failures

Manufacturers can significantly reduce restart risks by following a clear preventive maintenance plan. Here is a proven checklist to prepare for shutdown restarts:

·         Clean all machinery and remove dust or debris

·         Lubricate moving parts before startup

·         Inspect both mechanical and electrical systems thoroughly

·         Test controls and sensors before full production resumes

·         Stock essential spare parts to avoid long delays

·         Partner with industrial automation experts for technical support

Taking these simple steps ensures smoother restart and helps avoid costly breakdowns.

How Ralakde Helps

At Ralakde, we support manufacturers through every stage of the restart process. With over one million industrial automation parts in stock, we provide immediate availability of critical components. Our team delivers fast emergency repairs and refurbishments to get equipment back online quickly. We pride ourselves on reliable turnaround times that minimise downtime and reduce risk for manufacturers.

We also offer a critical spare stocking service, helping companies prepare for unplanned failures by ensuring the right parts are always on hand. By working with Ralakde, manufacturers gain a trusted partner that understands the importance of keeping production lines running.

Conclusion

Shutdown restarts do not have to be stressful or risky. With the right preventive maintenance plan and a reliable partner, you can avoid the most common machinery failures after shutdown. Preparation reduces downtime, saves money, and gives you confidence when production needs to restart at full capacity.

Get in touch with Ralakde today to secure your automation parts, repairs, and expert support before issues stop your production.