Getting Summer Shutdown Ready: Spare Parts and Stock

For many industrial sectors across the UK and Ireland, the summer months aren’t just about sunshine and reduced demand. They represent a vital window to carry out maintenance, upgrade systems, and reinforce long-term operational reliability. From food and beverage production lines to large-scale manufacturing facilities, summer shutdowns are often the only opportunity for teams to complete essential work that keeps critical systems running smoothly throughout the year.

Even the most carefully planned shutdowns can unravel if the right parts and stock are not available when needed. In a time of tight budgets, complex compliance requirements, and ongoing supply chain uncertainty, proactive stock planning is not just wise. It is essential.

The Importance of Planned Shutdowns

Planned summer shutdowns are a long-standing fixture in many sectors, particularly manufacturing. According to Make UK’s 2023 Manufacturing Outlook, 53 percent of UK manufacturers carry out shutdowns between June and August. These are used for statutory maintenance, safety inspections, retrofits, and systems upgrades that are impossible to perform during full operations.

Shutdowns create the space to:

• Replace or repair ageing infrastructure
• Clean and flush process systems
• Conduct legally required pressure and safety testing
• Upgrade piping, control systems, and plant layout
• Complete energy efficiency and decarbonisation improvements
• Reduce the risk of critical failure during peak demand periods

Planned downtime is a powerful tool, but it relies on precise execution. The average industrial shutdown in the UK lasts between 7 and 21 days.

Any delay in part supply, delivery or installation can cascade into higher costs, missed restart dates, and operational risk.

The True Cost of Delay

While unplanned downtime is often the headline-grabber, delays during planned maintenance periods can be just as damaging. A 2023 survey conducted by Asset Management Services UK found that:

• 43 percent of UK facilities experienced delays during their most recent shutdown
• The most common cause was missing or late spare parts
• Only 27 percent of sites had a formalised spare parts strategy

These delays translate into real losses. Data from Aberdeen Strategy & Research suggests the average cost of downtime in UK industrial settings is around £180,000 per hour.

Even in mid-sized facilities, the financial impact of a day’s lost production can range from £10,000 to £50,000.

Late or incorrect part deliveries also raise health and safety risks, increase the likelihood of rushed installations, and may even result in regulatory non-compliance if key inspections cannot be completed on time.

Strategic Stockholding: The Smarter Approach

The old approach to spare parts management was binary: either hold a large volume of everything or rely on emergency orders. Today, the focus is on criticality-based stockholding.

At IPS Flow Systems, we work with customers to classify their parts using a Criticality Matrix:

1. High-criticality parts

• Custom items or those with long lead times
• Failure halts production or breaches legal requirements Action: These should be held on-site or ringfenced with suppliers.

2. Medium-criticality parts

• More commonly available but still important to uptime Action: Keep accessible from a trusted supplier with confirmed availability.

3. Low-criticality parts

• Standard, non-essential, or easily sourced Action: Order as required but review periodically to prevent blind spots.

This structure prevents overstocking low-risk parts while ensuring availability of the components that genuinely keep your systems running.

Supply Chain: Still a Risk Factor in 2025

Although some of the acute supply chain challenges of recent years have eased, problems remain. According to the ONS Business Insights and Conditions Survey (February 2024):

• 18 percent of UK manufacturing businesses continue to face moderate or severe supply delays
• 28 percent say long lead times remain a significant operational barrier
• 19 percent have been forced to change suppliers due to availability or price shifts

When multiple sites plan maintenance during the same period, demand spikes for certain components. Items like actuated valves, pressfit fittings, drainage components, and high-performance plastic piping are all vulnerable to short-term shortages without prior planning.

Next-Day Stock Availability: A Competitive Advantage

Having a supplier who can deliver the right component the very next day is not just convenient. It is central to shutdown success.

IPS Flow Systems holds extensive UK stock across a wide range of product categories, including:

• PVC-U, PE, ABS, PVDF, and PP piping systems
• Valves and actuation
• RM Pressfit and SwissFluid solutions
• Kessel drainage systems
• Chemical dosing systems and accessories

With dedicated support teams, technical advisors, and same-day dispatch capabilities, we help businesses across the UK and Ireland stay in control of their summer shutdowns.

Get Prepared: Your Pre-Shutdown Checklist

Preparing for a shutdown takes more than ordering parts. Here is a checklist to guide your planning:

✅ Review your previous shutdowns. What caused delays or issues last time?

✅ Conduct a system audit. Identify ageing parts, known faults, or at-risk areas.

✅ Classify spare parts by criticality. Use a tiered approach to determine what must be held in stock.

✅ Review your suppliers. Are they equipped to provide next-day delivery? Can they reserve stock?

✅ Coordinate across teams. Maintenance, procurement, engineering, and compliance must be aligned.

✅ Communicate early. Let your supplier know what you need and when you need it.

Why It Matters More Than Ever

The pressure to run efficient, compliant, and sustainable operations is only growing. From AMP8 requirements in the water sector to increased scrutiny of fire safety systems in commercial buildings, maintenance programmes are more visible and more consequential than ever before.

Planned shutdowns are a chance to get ahead, but only if you can rely on your supply chain. Stock planning is no longer a back-office function. It is a key component of business continuity.

At IPS Flow Systems, we are proud to support shutdown success with the stock, service, and strategic input you need to deliver with confidence.

How IPS Flow Systems Can Help

At IPS Flow Systems, we understand that shutdowns don’t leave room for error. Whether you're upgrading ageing pipework, replacing critical components, or preparing for inspection, our team is here to ensure you have the right stock, advice, and delivery support to get the job done.

We go beyond simply supplying parts. We offer:

✔️ Extensive UK and Ireland Stockholding

From high-performance thermoplastics to chemical-resistant valves and fire protection systems, we hold thousands of essential products in stock — ready to ship next day. That includes:

• PVC-U, ABS, PE, PP, and PVDF piping systems - AGRU Kunststofftechnik GmbH Praher Plastics Austria GmbH Aliaxis UK
• Actuated valves and manual valve assemblies
• Raccorderie Metalliche Spa Pressfit systems for rapid, reliable installations
• Swissfluid AG d sampling and process valves
• KESSEL AG drainage solutions for complex layouts

✔️ Stock Reservation and Project Planning

We can reserve product specifically for your site shutdown. Simply tell us what you need, when you need it, and we’ll handle the rest — including timed deliveries, kit preparation, and phased drops by project area if required.

✔️ Technical Support and Product Advice

Not sure which system best suits your upgrade? Need guidance on compatibility or chemical resistance? Our technical experts are on hand to assist, helping you select the right product for longevity, safety, and compliance.

✔️ Responsive, Human Service

You won’t get stuck in a support loop. You’ll speak directly with experienced people who know your industry and understand your deadline pressures. And if there’s ever a last-minute change, we’ll work with you to find the fastest, most practical solution.

Let’s talk about your summer plans now. 📧 sales@ipsflowsystems.com 📞 UK: 0191 521 3111 📞 Ireland: +353 1 2573741 🌐 www.ipsflowsystems.com

References

1. Make UK Manufacturing Outlook Report (2023) – www.makeuk.org
2. Asset Management Services UK Maintenance Survey (2023) – www.assetms.co.uk
3. ONS Business Insights and Conditions Survey (February 2024) – www.ons.gov.uk
4. Aberdeen Strategy & Research (2022). "The Cost of Downtime in Manufacturing" – www.aberdeen.com
5. British Standards Institution (BSI) – Guidelines on preventive maintenance and plant compliance – www.bsigroup.com
6. Institute of Asset Management – Strategic Spare Parts Management Framework – www.theiam.org