My operation Lost over $100,000 in One Day Because of This Overlooked Failure – Don’t Make the Same Mistake!

It’s always the simple things that come back to bite you.

I’ve seen this too many times in both food and beverage facilities: a small leak at a valve or gasket that’s ignored until it triggers a massive failure. One day, it cost me over $100,000 in product loss and downtime. It could’ve easily led to a recall. And even worse, it could’ve injured someone.

That minor drip? It’s your early warning sign. Fixing it takes minutes. Ignoring it could destroy product, halt production, send contaminated product out the door, or injure an employee.

Want to prevent this? Start here:
–       Conduct daily end-to-end walks of your facility, and layer responsibility across shifts and departments to catch leaks early.
–       Review your PM program to make sure gaskets and valve components are replaced on schedule.
–       Never use makeshift tools like adjustable wrenches on clamps. It allows for over-torquing the clamp and weakens the hinge and causes failure.
–       Create an escalation process—pause production when a leak is spotted to minimize impact.
–       After gasket replacement and valve rebuilds, spot check rubber components for wear or defects.
–       Use OEM parts only. Yes, they cost more, but inexpensive replacement parts have caused some of the biggest failures I’ve seen.
–       Inspect valves and clamps during sanitation, SIP, and production—not just when there’s a problem.

The bottom line, preventive maintenance and daily discipline prevent millions in losses and protect your people.

That slow drip? It’s trying to tell you something.

Head to the floor today. Look closely. Find it before it finds you.

This is an AI generated photo.