Since commissioning, a critical milk separator experienced recurring water contamination in the gearbox, ultimately resulting in a catastrophic failure and significant production disruption. A detailed cause‑tree investigation was undertaken to identify the primary failure mechanism and contributing factors. This analysis enabled a low‑cost engineering control to be implemented that eliminated the root cause of failure. In addition, a practical oil health monitoring program was introduced, incorporating improved visual inspections, oil sampling and crackle testing. These actions restored equipment reliability, reduced business risk and delivered high confidence in long‑term separator health within tight cost and resource constraints.

After the works complete, the site team has better understanding and ownership of the equipment, which was previously perceived as 'the contractor's problem'.