Case Study

Claim Reduction Over $9M

Explosion at Ethanol & Ethanol Co-Products Plant

Case Study

Explosion

Services Provided

Project Management

A complex network of industrial pipes in a facility. Red, yellow, and metallic pipes with valves and gauges suggest an active system. Utilitarian tone.
Interior of an industrial facility with large metal ducts, beams, and red railings. The space appears spacious, organized, and illuminated by bright lights.
Industrial interior with metal walkways and red railings. Machinery and pipes fill the space, creating a complex, busy atmosphere. Bright lighting.
Industrial interior with large machinery featuring a cylindrical drum, metal walkways, and red railings.
Large, damaged industrial tank inside a warehouse, with scorched metal and debris around, suggesting a fire incident. Sunlight filters through roof gaps.
Industrial machinery with damaged metal panels and burnt insulation, inside a factory. The scene suggests recent fire damage, creating a sense of neglect.
Large industrial metal silos in a warehouse with gray walls and exposed pipes. A red ladder extends vertically. The space appears clean and organized.

The Situation

A major explosion occurred at an ethanol plant, severely damaging specialty ethanol co-products processing equipment. As a result, the client faced loss of revenue for its co-products.

Equipment Impacted

  • Rotary Dryers
  • Conveyance Systems
  • Gas Trains
  • Thermal Oxidizer
  • Cyclones
  • Electrical Distribution

Value-Driven Solutions

Took Immediate Control of the Restoration Process

Initiated daily meetings with restoration firms, the insured, and client to remove obstacles, streamline equipment assessments, and accelerate repair vs. replacement decisions.

Ongoing Cost and Contract Oversight

Conducted detailed reviews of contracts, costing proposals, and invoices—identifying multiple errors and non-loss-related charges to ensure accurate and justified expenditures.

Equipment Restoration Oversight

Closely monitored schedule adherence, proactively addressing delays by quickly identifying and removing barriers, which significantly improved project timelines.

Ethanol plant by corn field

The Results

Reduced Costs

$16.13M restoration cost vs. $25.5M RCV initial loss estimate.

Smart Asset Decisions

Strategic repair/restoration decisions expedited restoration timeline.

Client Confidence

Reinforced ILC’s role as a trusted partner in high-stakes ethanol plant losses.

Case Studies

Real Claims, Real Results

Fire Damage on Aluminum Casing Line

Solution to Repair Instead of Replace Reduced Claim By $1.5M

Breakdown of CNC Machine

Repair vs. Replace Solution Reduces Claim By $600,000

Damaged Car Wash Systems

Reduced Claim by $32K

Damaged in Transit - Corrugated Box Making Machine

Missing seals and transit mishandling

Explosion at Condo Association

$1M+ in Equipment Retained Through Repair vs. Replace

Explosion at Ethanol and Ethanol Co-Products Plant

Claim Reduction Over $9M

Explosion at Ethanol and Ethanol Co-Products Plant

Reduced Claim By Nearly $6M

Explosion in Saturator Converting Line

Prevented $12 million in Business Interruption

Fire at Chemical Processing Facility

Lead Time and Reduction by Over $15M

Fire at Livestock Rendering Plant

Uncovered $4.5M in Betterments

Fire Damage at Concrete Batch Plant

Repair vs. Replace Significantly Reduces Claim Costs

Fire Damage on Film Line

Lead Time Cut by 14 Months, Reducing Costs by Over $1.5 Million

Fire Damage on Metal Processing Equipment

Reduced Claim Cost by over $700,000

Fire Damage with Healthcare Equipment

97% Reduction in the Claim

Fire in Electrical Control Systems

Reduced Claim by Nearly $1M

Fire Loss of Life Science Equipment

Reduced Claim Costs More Than $3.5M

Fire/Water Damage at Aluminum Beverage Can Manufacturing

Result in Reduced Claims Cost of Nearly $3M

Flood Loss at Indoor Water Park

Reduced Claim by $400k with Pre-existing Findings

Freezing Pipes & Water Damage In Boiler System

Solution to Repair Mitigates BI and Reduces Claim Over $85,000

Hail Storm at Manufacturing Facility

$11k Repair Instead of $800k Replacement

Lighting Surge at Packaging and Printing Facility

Restoring to Pre-loss Reduced Claim by $2.9M

Mechanical Breakdown at Gun Manufacturing Facility

Reduced Business Interruption by 14 weeks

Mechanical Failures on Horizontal Grinder

Identified Failures Stemming from Inadequate Repairs

Tornado Hits Agricultural Equipment Manufacturer

ROM Reduced by Millions with ILC’s Involvement

Water Damage at Chemical Feed Water Line

$1.6M Reduction in Pre-existing Conditions

Water Damage to MRI Machine

Medical Equipment Repair Costs Reduced by over $100,000.

Water Damage with Fire Pump System

Reduced Repair Cost by almost $4k

The Experts Behind the Best Outcome.

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