How does effective maintenance contribute to the energy transition, particularly in reducing emissions and improving efficiency?

Effective maintenance today is about far more than simply preventing equipment from breaking down. At John Crane, our mission is to keep critical operations running safely, efficiently and sustainably. That means helping customers maximise the performance of their existing infrastructure – improving efficiency and reliability, while cutting emissions, without the need for major overhauls. 

Decarbonisation isn’t always about adopting new energy sources. Often, it’s about making existing assets work harder and smarter. Well-maintained equipment runs cleaner, lasts longer and consumes less energy. Imagine a system that leaks less, breaks down less and simply performs better. By identifying issues early and avoiding unnecessary shutdowns, modern maintenance becomes a powerful lever for decarbonisation – keeping operations efficient and reducing their carbon footprints.

With advancements like remote monitoring and smart diagnostics, there’s also less need for travel to remote or hazardous sites – cutting emissions and improving safety. The financial benefits are compelling too: reduced downtime and longer equipment life often translate into significant cost savings.

What role do technologies like condition monitoring and predictive analytics play in sustainability performance?

They’re playing an increasingly pivotal role. As industries are asked to deliver more – greater output, lower emissions and tighter margins – condition-based and predictive maintenance are gaining traction fast. The global industrial maintenance market is booming – estimated at $54.47 billion in 2024 and expected to nearly double by 2034. Predictive maintenance alone is growing around 35% annually, which says a lot about its value.

Traditional maintenance is typically time-based and reactive. Condition monitoring flips that model. With real-time data and predictive analytics, companies can act only when it’s needed, avoiding unnecessary interventions, unexpected failures and the energy waste that comes from inefficient performance. 

Our John Crane Sense® platform, which includes John Crane Sense Monitor and Sense Turbo, brings this to life. Think of them as the digital ‘eyes and ears’ of industrial equipment, using sensors and advanced analytics to detect early signs of wear or failure. Operators gain real-time visibility into the health of their equipment, empowering them to act before problems escalate – better energy performance, lower emissions and more reliable operations.

As industries scale up low-carbon initiatives like hydrogen and carbon capture, what are the biggest challenges they face in integrating advanced maintenance solutions?

One of the biggest hurdles is complexity. New, low-carbon technologies such as hydrogen and carbon capture introduce new processes and materials, which demand highly specialised maintenance strategies. Operators must ensure consistent reliability, meet strict safety and emissions standards, and adopt the right digital tools – often simultaneously. 

We’re actively supporting this transition. Our sealing and filtration solutions are engineered to perform under the demanding conditions of CO₂ compression and transport – critical in CCUS and hydrogen applications. Collaboration is key. For example, our partnership with Franco Tosi Meccanica is focused on supercritical CO₂ power cycles to push efficiency and cut emissions in power generation.

But there’s also a mindset challenge. Maintenance is still too often viewed as a cost rather than a strategic investment. The organisations making the most progress are those embedding maintenance and predictive analytics into their broader sustainability strategies – not just fixing things when they break but using it as a tool to deliver long-term environmental and business performance. 

Can you share examples or case studies where John Crane’s technologies, such as John Crane Sense Monitor and Sense Turbo, have improved operational efficiency and environmental impact?

One great example is our work with a major liquefied natural gas (LNG) producer in South America. They were facing costly unplanned downtime that impacted both operational efficiency and environmental goals. We helped them implement our John Crane Sense Turbo solution, with its embedded sensors and real-time monitoring, to keep tabs on compressor seal health.

The results were impressive: they cut unplanned downtime by eight days and avoided around $4 million in production losses. Beyond the financial return, the customer gained visibility into asset performance, improved maintenance planning, and avoided unnecessary disruptions – leading to a cleaner, more efficient operation overall.

Our technologies help customers improve plant efficiency, enhance reliability and reduce emissions without the need for major overhauls. Whether it’s advanced sealing, filtration or digital monitoring, we’re helping customers get more from their equipment while reducing their environmental impact.

Looking ahead, how do you see maintenance evolving to meet future sustainability goals and regulatory pressures?

Maintenance is becoming smarter, more connected and more essential to sustainability than ever. We’re now moving beyond preventative maintenance towards intelligent, predictive and increasingly prescriptive approaches. By combining advanced data, advanced algorithms and automation, it’s possible to detect issues early, recommend interventions, and in some cases, automate next steps before problems arise. This means fewer outages, better energy efficiency and longer asset life.

With new regulations like the EU’s Clean Industrial Deal and the Corporate Sustainability Reporting Directive (CSRD), companies are under real pressure to deliver measurable decarbonisation. Smart maintenance will be vital for hitting those targets, from carbon reporting to long-term asset optimisation.

We’re excited about what’s next. Our John Crane Sense platform is already making a difference, and we’re constantly building on it by adding new technology, refining our analytics, and always looking for ways to help customers become more resilient. Maintenance is a powerful lever for decarbonisation and resilience, and those who embrace it will be best placed to meet both regulatory demands and their own sustainability ambitions.