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Why Your Production Line Keeps Failing at the Worst Possible Time (and What You Can Do About It)

3/5/2026 12:25 PM

Production monitoring systems are great at reporting current states. Temperatures, pressures, and flow rates are all displayed in real-time and have alarms set for threshold violations. But they're designed to catch failures in progress, not failures in development...

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Posted By: cstupica@aci-controls.com

From Gas Train to Spare Parts: How ACI Protects Combustion Uptime from Design Through Daily Operations

2/26/2026 11:34 AM

Most combustion system projects end at commissioning. Your equipment gets installed, the burners light off, the control panel checks out, and the integrator moves on to the next job. What happens after that is largely left to you.At ACI...

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Posted By: cstupica@aci-controls.com

Preventing Million-Dollar Delays in Planned Power Outages: 6-Phased, 90-Day Approach

1/21/2026 8:53 AM

Every day your plant stays offline during an outage costs between $50,000 and $100,000 in lost energy sales. For nuclear facilities, that figure climbs past $1 million. Yet roughly 60% of unplanned shutdowns stem from preventable equipment failures...

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Posted By: cstupica@aci-controls.com

The Hydrogen Power Generation Playbook: 5 Decisions That Determine Success

1/7/2026 10:04 AM

In the quarterly earnings call, your CEO just announced the company’s 2030 net-zero commitment… and that it’s your job to make it happen.So now you’re sweating as you sit amongst executives, expecting you to create...

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Posted By: cstupica@aci-controls.com

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Posts

Why Your Production Line Keeps Failing at the Worst Possible Time (and What You Can Do About It) [03/05/26 12:25 PM]

From Gas Train to Spare Parts: How ACI Protects Combustion Uptime from Design Through Daily Operations [02/26/26 11:34 AM]

Preventing Million-Dollar Delays in Planned Power Outages: 6-Phased, 90-Day Approach [01/21/26 08:53 AM] The Hydrogen Power Generation Playbook: 5 Decisions That Determine Success [01/07/26 10:04 AM]

Inventory Control Techniques to Make Sure You Have What You Need When You Need It [10/30/25 10:05 AM] Supply Chain Risk Management: Don't Let a Missing Part Shut Down Your Operation [10/20/25 03:59 PM] Equipment Management Strategies That Save Your Budget and Keep Production Running [10/01/25 03:30 PM]

Preventative Maintenance Strategies That Keep Your Manufacturing Operations Running Smoothly [09/17/25 09:23 AM] Industrial Automation Trends to Watch: Your Guide to Staying Competitive in 2026 [09/03/25 08:25 AM]

How Automation and Process Optimization Turn Reactive Operations Into Smooth Manufacturing [08/15/25 03:06 PM]

Equipment Reliability Best Practices: How to Prevent Costly Downtime and Become the Company Hero [07/28/25 09:55 AM] Parker Instrumentation Solutions (for Manufacturing Process Control Challenges) [07/03/25 11:34 AM]

8 Preventative Maintenance Tips for Differential Pressure Sensors [06/23/25 03:38 PM] Understanding Industrial Distribution: Supply Chain Dynamics Explained [06/03/25 09:11 AM]

Top-5 Innovations in HMI Programming That Boost Factory Efficiency [05/08/25 10:10 AM] Original Equipment Manufacturers: Building Partnerships with Distributors [05/06/25 12:50 PM]

How Industrial Automation Can Improve Workplace Safety [04/29/25 02:15 PM] Costs, Causes, and Cures for Manufacturing Downtime [04/28/25 02:16 PM] The Future of Industrial Process Control: Advanced Technologies to Watch Out For [04/10/25 11:17 AM]

An Overview of Industrial Process Control Systems and Their Applications [03/12/25 04:14 PM]

Advanced Process Control Solutions: Boosting Efficiency in Modern Manufacturing [02/21/25 08:53 AM] Understanding Control Valves: What They Are and Why They Matter [02/03/25 11:22 PM] The Benefits of Working with a Leading Control Panel Supplier [02/03/25 11:11 PM]

What Causes Low Differential Pressure and How Can You Test It? [01/13/25 10:54 PM]

How Variable Frequency Drives Save Energy [07/16/24 11:51 AM] The 8 Main Types of HMI Screens and When to Pick Each One [07/16/24 11:48 AM] Process Control, Automation, and the Role of PLCs [07/16/24 11:47 AM] Buyer's Guide: Variable Frequency Drives [07/16/24 11:46 AM] Buyer's Guide: Everything you need to know about IDEC Relays [07/16/24 11:43 AM] Explaining the Difference Between HMI, PLC, and SCADA [07/16/24 11:41 AM] The 8 Services an Industrial Distribution Company Can Provide to You [07/16/24 11:33 AM]

Elevating Customer Experience in Industrial Process Control Distribution: Top Expectations for Distributors [03/04/24 01:59 PM] The Advantages of Partnering with ACI Controls as your Industrial Products Stocking Distributor [03/04/24 01:37 PM] The Value of Continued Process Application and Skill Set Training for Manufacturing Maintenance Departments [03/04/24 01:26 PM] Navigating the Complexities of Burner Control Management in Furnace Processes [03/04/24 12:50 PM] 10 Advantages of Using Variable Frequency Drives (VFDs) [03/04/24 12:35 PM] Navigating Process Filtration Products in the Food and Beverage Industry: Requirements and Challenges [03/04/24 12:26 PM] The Top 10 Benefits of On-Site Nitrogen Generators for Manufacturing Processes [03/04/24 12:10 PM] Pipe Heat Tracing [03/04/24 10:38 AM] Improving Manufacturing Efficiency: A Guide to Process Control [03/01/24 10:48 AM]

Unleashing The Power Of Data Acquisition Systems In Manufacturing [01/16/24 11:43 AM]

Protecting Your Investment: The Critical Role of Balston Air and Gas Filters in Industrial Equipment [12/07/23 09:52 AM] Cleaner, Smarter and More Efficient Filtration Solutions [12/03/23 10:42 PM] Combustion Air Blowers [12/01/23 10:23 PM]

Supplier Spotlight: Honeywell [11/15/23 10:12 PM]

Prioritization and Criticality in Manufacturing: What it Means to You [08/28/23 11:37 AM] Chart Recorders: What Are They and How Can They Help You Collect Accurate Data [08/15/23 11:19 AM]

Everything You Need to Know About Fuel Water Separators (and Why Maintenance is Critical) [06/20/23 03:12 PM] The Differential Pressure Guide: The Basics You Need to Know [06/15/23 02:43 PM]

What is Predictive and Preventive Maintenance and Why You Should Care [05/30/23 03:00 PM]

Liquid Nitrogen Generators: What Are They and How Do They Work? [04/15/23 03:19 PM]

What You Need to Know About Industrial Burners [03/21/23 12:17 PM] Differential Pressure Switches: What You Need To Know [03/01/23 09:10 PM] Buyer's Guide: What to Know Before Buying Temperature Transmitters [03/01/23 09:01 PM]

PLCs in Manufacturing [01/18/23 05:11 PM] Why Choose Single Ferrule Tube Fittings for Vibration Protection and Temp Cycling [01/11/23 01:10 PM] HMIs: What Are They and How to Use Them [01/11/23 10:10 AM]

Buyers’ Guide: What to Know About Buying Compressed Air Dryers [11/10/22 04:33 PM]

HOW TO STAY SAFE IN INDUSTRIAL HEATING APPLICATIONS [09/30/21 03:47 PM] 3 WAYS THAT PPE WILL KEEP YOU SAFE IN THE WORKPLACE [09/28/21 03:35 PM] HOW TO PREVENT CORROSION IN OIL AND GAS APPLICATIONS [09/28/21 01:29 PM]

HOW TO IMPROVE INDOOR AIR QUALITY IN YOUR FACILITY [08/20/21 11:15 AM] EVERYTHING YOU NEED TO KNOW ABOUT SINGLE FERRULE TUBE FITTINGS [08/19/21 04:05 PM] THE IMPORTANCE OF PARKER’S SUPARCASE FERRULE HARDENING [08/12/21 02:57 PM]

THE 4 MOST IMPORTANT SOURCES OF COMPRESSED AIR CONTAMINATION [07/07/20 03:53 PM]

THE EIGHT WASTES OF LEAN MANUFACTURING AND HOW TO TACKLE THEM [06/04/20 03:53 PM]

WHAT YOU NEED TO KNOW ABOUT FILTRATION IN THE FOOD AND BEVERAGE INDUSTRY [05/19/20 04:01 PM] WHAT YOU NEED TO KNOW WHEN SELECTING THE RIGHT INSTRUMENTATION TUBING [05/04/20 04:13 PM]

EVERYTHING YOU NEED TO KNOW ABOUT THE HEAT TREATING PROCESS [04/17/20 04:37 PM] THE IMPORTANCE OF CONDITION MONITORING IN THE FOOD INDUSTRY [04/09/20 04:40 PM]

WHY SUSTAINABLE TECHNOLOGY IS SO IMPORTANT IN THE POWER INDUSTRY [03/18/20 04:48 PM] THE MOST CORROSION-RESISTANT METALS FOR YOUR EQUIPMENT [03/02/20 04:53 PM] HOW TO BOOST STEAM GENERATION EFFICIENCY WITH GUIDED WAVE RADAR [03/02/20 04:52 PM]

HOW TO KEEP YOUR DUST COLLECTOR OPERATING AT ITS HIGHEST CAPACITY [02/04/20 05:00 PM]

THE TOP 5 TRENDS THAT WILL TAKE OVER THE INDUSTRY THIS YEAR [01/31/20 05:35 PM] HOW TO CHOOSE THE BEST CONNECTION TYPE IN SINGLE-USE SYSTEMS [01/03/20 05:39 PM]

BACK TO THE BASICS: 5 IMPORTANT CLASSIFICATIONS OF COMBUSTION [12/16/19 05:45 PM] HOW TO AVOID TURBINE FAILURES IN LNG PROCESSING PLANTS [12/02/19 05:49 PM]

THE MOST COMMON TYPES OF CORROSION AND HOW TO HANDLE IT [11/18/19 05:55 PM]

HOW TO REDUCE DUST COLLECTOR MAINTENANCE IN THE CEMENT INDUSTRY [10/28/19 06:00 PM] 3 REASONS WHY INDUSTRIAL FURNACES ARE THE RIGHT SOLUTION [10/02/19 06:11 PM] HOW TO INCREASE PLANT EFFICIENCY WITH ENERGY MANAGEMENT [10/01/19 06:14 PM]

4 THINGS YOU NEED TO KNOW ABOUT MAXON VALVES IN COMBUSTION SYSTEMS [09/16/19 12:10 PM] THE TOP 5 WAYS TO OPTIMIZE WATER MONITORING [09/03/19 12:16 PM]

HOW TO AVOID CORROSION IN METAL PARTS [08/19/19 12:33 PM] SAVE ENERGY AND PREVENT DISRUPTIONS WITH NITROGEN GENERATORS [08/05/19 12:39 PM]

THIS IS HOW STERILE FILTRATION IS CHANGING THE INDUSTRY [07/23/19 03:41 PM] HOW TO KEEP YOUR ELECTRICAL CABINETS DRY IN THE FOOD INDUSTRY [07/08/19 03:45 PM]

EVERYTHING YOU NEED TO KNOW ABOUT VALVES IN THE FOOD INDUSTRY [06/17/19 03:50 PM]

HOW TO CHOOSE A WATER TREATMENT SYSTEM SUPPLIER FOR POWER GENERATION [05/30/19 03:53 PM] CASE STUDY: HOW TO SOLVE TEMPERATURE CONTROL ISSUES IN A THERMAL OXIDIZER [05/13/19 04:02 PM]

A NEW ENERGY EFFICIENT NITROGEN GENERATOR IS LAUNCHING [04/29/19 04:10 PM] 3 DIGITIZATION TRENDS TO LOOK OUT FOR IN THE OIL AND GAS INDUSTRY [04/09/19 04:11 PM] THE IMPORTANT KEY TO SUCCESSFUL NEW IOT TECHNOLOGY [04/01/19 04:16 PM]

ALL THE BENEFITS OF ACI’S NEW INSTRUMENT GAS SUPPLY COLUMN [03/19/19 01:57 PM]

WHY FILTRATION IS SO IMPORTANT IN THE OIL AND GAS INDUSTRY [02/26/19 02:03 PM] WHY CHECK VALVES ARE SO IMPORTANT FOR HYDRAULICS [02/13/19 02:04 PM] 3 REASONS WHY SUSTAINABILITY IS IMPORTANT FOR MANUFACTURING [02/04/19 02:08 PM]

ALL OF THE HIDDEN COSTS OF GAS CYLINDERS [01/14/19 10:25 PM] THE TOP MANUFACTURING TRENDS TO WATCH OUT FOR IN 2019 [01/02/19 02:22 PM]

HOW TO BE SAFE WHEN WORKING WITH COMPRESSED NITROGEN GAS [12/17/18 02:25 PM] WHY CALIBRATION IS IMPORTANT FOR MANUFACTURERS [12/05/18 02:28 PM]

IS STAINLESS STEEL WORTH THE RISK IN FILTRATION? [11/20/18 02:38 PM] THE BEST TIPS FOR EXTENDING YOUR EQUIPMENT’S LIFESPAN [11/06/18 02:40 PM]

WHY STERILE FILTRATION IS BETTER FOR ULTIMATE SUSTAINABILITY [10/15/18 02:43 PM] 3 TRENDS IN THE OIL AND GAS INDUSTRY TO WATCH OUT FOR [10/03/18 02:46 PM]

MAKE THE BEST SAFETY PLAN FOR COMPRESSED GAS [09/17/18 02:50 PM] EVERYTHING YOU NEED TO KNOW ABOUT THE INTEGRATION OF CONTROL SYSTEMS [09/06/18 02:56 PM]

EVERYTHING YOU NEED TO KNOW ABOUT HEAT TRACING [08/14/18 03:00 PM] THE IMPORTANCE OF WATER CHILLING IN MANUFACTURING [08/02/18 03:00 PM]

ALL OF THE BENEFITS SURROUNDING COMPRESSED AIR FILTERS [07/16/18 03:09 PM] WHY MANIFOLDS ARE SAVING THE DAY FOR ENGINEERS [07/05/18 03:13 PM]

THE IMPACT OF ROBOTIC TECHNOLOGY IN THE MANUFACTURING INDUSTRY [06/22/18 03:18 PM] HOW TO ENSURE SAFER BOTTLED WATER WITH MICROFILTRATION [06/07/18 03:23 PM]

HOW TO BOOST COST-EFFECTIVENESS IN MANUFACTURING [05/24/18 03:31 PM] HOW TO REDUCE LEAD FOUND IN ANIMAL WATERING SYSTEMS [05/11/18 03:34 PM]

4 WAYS TO IMPROVE YOUR MANUFACTURING EMPLOYEES’ HEALTH [04/24/18 03:40 PM] WHY CONDITION MONITORING IS IMPORTANT FOR YOUR BUSINESS [04/10/18 03:43 PM] HOW TO IMPROVE PRODUCTIVITY IN MANUFACTURING [04/04/18 03:53 PM]

HOW TO USE PARKER’S THM ANALYZER TO IMPROVE DRINKING WATER SAFETY [03/30/18 03:56 PM]

5 MANUFACTURING APPS GUARANTEED TO IMPROVE YOUR PROCESSES [02/28/18 04:01 PM] HOW TO CHOOSE THE RIGHT CONNECTOR AND TUBING FOR YOUR APPLICATION [02/08/18 04:06 PM]

4 POWERFUL MANUFACTURING SAFETY TIPS EVERY PLANT NEEDS [01/30/18 09:48 PM] HOW TO PICK COMPRESSED AIR TREATMENT SOLUTIONS [01/24/18 09:49 PM]

TEN STEPS TO LEAK-FREE CONNECTIONS IN OIL AND GAS APPLICATIONS [12/15/17 09:56 PM] EVERYTHING YOU WANT TO KNOW ABOUT THERMAL MASS FLOW [12/14/17 09:53 PM]

HAVE YOU HEARD? ALL INLINE BALL VALVES ARE CERTIFIED TO NSF/ANSI 61 [11/16/17 10:02 PM] WHAT YOU NEED TO KNOW ABOUT BACK PRESSURE SAFETY VALVES [11/09/17 10:08 PM]

HOW TO STREAMLINE YOUR CONDITION MONITORING PROCESS [10/27/17 10:11 PM] HOW TO MIX MATERIALS IN CORROSIVE ENVIRONMENTS [10/13/17 10:15 PM]

5 BIG REASONS TO SWITCH TO OPTICAL DO MEASUREMENT [09/27/17 10:23 PM] HOW TO USE NITROGEN GENERATORS FOR FOOD PRESERVATION [09/14/17 10:27 PM]

3 IMPORTANT REASONS TO USE SMARTLINE TRANSMITTERS [08/24/17 10:33 PM] WHAT YOU NEED TO KNOW ABOUT DOWNSTREAM OIL AND GAS FILTRATION [08/09/17 10:39 PM]

4 BIG BENEFITS OF PROCESS CONTROL INSTRUMENTATION [07/25/17 10:47 PM] THE COMPLETE GUIDE TO THE BEST PROCESS CONTROL PRACTICES [07/06/17 10:47 PM]

5 THINGS YOU NEED TO KNOW ABOUT THE PROCESS CONTROL INDUSTRY [06/22/17 10:50 PM] HOW TO AVOID RISK OF IGNITION WHEN OXYGEN IS PRESENT IN VALVE APPLICATIONS [06/15/17 10:55 PM]