Case Study

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

Fire Damage on Film Line

Case Study

Fire Damage

Services Provided

Project Management
BI-Mitigation
Repair vs. Replace

Fire Damage on Film Line
Fire Damage on Film Line
Fire Damage on Film Line
Fire Damage on Film Line
Fire Damage on Film Line

The Situation

The fire caused serious damage toa specialized production system, one of only 12 like it in North America. The seven-story-tall system employed complex processing methods that were difficult to understand. Because the OEM was no longer in business, there was little documentation or technical support available. Replacing the entire system was estimated to take 18 months and cost more than $3.5 million. During this period, the plant would have to operate at half its normal capacity, resulting in significant BI, increased exposure, and higher financial risk.

Equipment Impacted

  • Production Line Assembly

  • Process Machinery

  • Processing Stations

  • Conveyance Systems

  • Structural Equipment

  • Electrical Distribution

Value-Driven Solutions

Reverse Engineering and Repair Feasibility

A full, top-to-bottom evaluation of the production line was conducted to identify fire-damaged components and assess rebuild feasibility. Technical specialists located and collaborated with former OEM personnel to recover critical design and operational information.Electrical diagnostics and detailed inspections were leveraged to identify hidden damage and support accurate restoration planning.

Rebuild Strategy and Cost Stabilization

Reverse engineering techniques were applied to reconstruct the missing design and repair documentation, enabling the development of a structured rebuild plan. A comprehensive repair methodology was established with a detailed timeline and cost projections, enabling informed decision-making amid limited documentation and high operational risk.

Non-Invasive Project Coordination

Restoration planning was coordinated to minimize disruption to the remaining production line and plant operations. Ongoing coordination between repair teams, engineering resources, and stakeholders ensured efficient scheduling, reduced plant impact, and consistent communication throughout the rebuild process.

Fire Damage on Film Line

The Results

Reduced Exposure and Stable Restoration Costs

A rebuild strategy was established at approximately $1.9 million compared to the projected $3.5 million replacement cost, providing a stable and reliable restoration cost from initial assessment through project completion.

Accelerated Production Recovery

Reverse engineering and targeted rebuild planning reduced the restoration timeline to approximately four months compared to the estimated 18-month replacement timeline, significantly limiting production downtime.

Minimized BI Impact

The restoration approach allowed the facility to maintain operational continuity on the remaining production line with minimal disruption, preventing compounded capacity losses and supporting ongoing business performance.

Case Studies

Real Claims, Real Results

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

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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

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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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