Reverse Engineering Capability

Case Study • Reverse Engineering

Restoring Production Stability Through Reverse Engineering

3D Scanning, Digital As‑Builts, and Local Manufacturing for Obsolete Plant Equipment

Executive Summary

A leading paper and pulp company in South Africa faced recurring equipment failures causing extended outages. Replacement parts were no longer available because the equipment had become obsolete, and no as-built information existed to support repairs or replication. With limited capital for major upgrades and no ability to shut down the plant for extended periods, AQRESS was appointed to deliver a practical reverse engineering solution. AQRESS implemented a two-stage approach: first, a rapid intervention using 3D scanning to create accurate digital models and as-built drawings, enabling local manufacture of critical parts and reducing lead times. Second, AQRESS worked with the client to develop a capital replacement strategy that delayed major capital spend by nearly five years while maintaining production stability and allowing revenue growth to support future upgrades. The project demonstrated AQRESS’ application of reverse engineering principles and technologies such as 3D scanning and additive manufacturing, saving the client millions while improving operational resilience.

Problem Statement

The client’s plant contained critical assets that repeatedly failed and required urgent replacement parts with the following key challenges:

Obsolete equipmentEquipment was obsolete, with limited or no OEM support.
No as-builtsNo as-built drawings or documentation were available.
Extended outagesRepairs were difficult to implement, leading to extended outages.
Revenue lossOutages directly resulted in revenue loss.
Limited capitalThe client faced limited capital for major upgrades.
Limited shutdown windowsThe plant could not be shut down for extended periods to enable major replacement works.

Our Approach: A Two‑Stage Reverse Engineering Strategy

Stage 1: Rapid Recovery Through Digital As‑Builts and Local Manufacturing

AQRESS implemented an accelerated recovery plan to reduce downtime and stabilize production:

  • 3D scanning of affected sections of the plant to capture accurate geometry
  • Development of 3D models and as-built drawings to rebuild missing engineering documentation
  • Engineering verification and design refinement to ensure manufacturability and fit
  • Enablement of local manufacturing of replacement parts, reducing reliance on overseas lead times and minimizing capital requirements

This stage delivered a practical way to restore and maintain operations without extended shutdowns.

Stage 2: Capital Replacement Strategy (Deferred Spend, Managed Risk)

To address long-term sustainability and recurring risk, AQRESS worked with the client to develop a structured strategy for capital replacement:

  • Prioritized replacement roadmap based on risk, failure impact, and production criticality
  • Strategy to delay major capital replacement by nearly five years
  • Alignment of replacement timing with business cash flow; allowing increased revenue to help fund future capital expansion and upgrades

This approach reduced immediate financial strain while supporting a controlled transition to modernized equipment.

The Team

AQRESS deployed a multidisciplinary team aligned to both rapid recovery and long-term planning:

Project Manager Control and Instrumentation Engineers Mechanical Engineers Electrical Engineers Draughtspersons 3D Scanning Specialists

Results & Impact

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Faster Repairs

Reduced outage risk by enabling faster repair cycles through locally manufactured parts.

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As‑Built Confidence

Re-established engineering confidence through accurate 3D models and as-built drawings.

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Deferred Capex

Avoided immediate major upgrades and delayed large capital spend by nearly 5 years.

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Production Stability

Maintained production stability and reduced revenue loss exposure.

Why Partner with AQRESS

Reverse engineering expertisePractical capability for obsolete and undocumented assets.
Advanced capture technology3D scanning and digital modeling to recreate missing plant intelligence.
Multidisciplinary engineeringMechanical, electrical, and control domains integrated for brownfield delivery.
Execution under constraintsProject management discipline with minimal shutdown windows.
Local manufacturing enablementReduced lead times and improved cost control.
Strategic asset planningLinking technical decisions to financial realities and business continuity.

Expanding Adoption Across Industries

AQRESS is now supporting clients in mining, energy, and petrochemical industries to optimise their assets and defer capital expenditure through the same approach. The approach also simplifies the implementation of digital twins and predictive maintenance approaches due to availability of data and digital assets.

Next Steps

If your operations are impacted by obsolete equipment, missing drawings, long lead times, or recurring failures, AQRESS can help you stabilize production quickly while building a financially realistic path to modernization.

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