What is Laser Alignment and why it matters for your plant equipment

When it comes to rotating machinery, like motors, pumps, compressors, gearboxes or fans, correct shaft alignment is absolutely critical. Misaligned shafts are one of the most common root causes of equipment failures and maintenance headaches. That’s where laser alignment comes in.

What is Laser Alignment?
Laser alignment is a precision measurement technique used to ensure the rotating shafts in coupled machinery are geometrically aligned, meaning their rotational centrelines are collinear and orientated correctly, whether the machine is static or operating under load.

Laser alignment systems use laser beams and sensors to measure shaft position, angularity, and offset. These measurements are incredibly accurate, within fractions of a millimetre, and allow technicians to detect even small misalignment issues that would likely be missed with traditional methods.

Because of this precision, laser alignment ensures the machinery operates within design specifications, under optimal alignment conditions.

Why Laser Alignment is important for your equipment
Using laser alignment is not just a “nice to have”, it delivers tangible operational benefits including:

• • Reduced vibration, wear and tear
    Misaligned shafts create uneven loads and stresses on bearings, seals, couplings, and shafts. That stress can cause excessive vibration, heating, premature wear, or even failure of critical components. Proper laser alignment dramatically reduces these stresses, extending the life of bearings, seals, couplings, and other parts.

• • Improved efficiency and energy savings
    Misalignment increases friction and inefficient power transmission, forcing motors to work harder. That leads to higher energy consumption and wasted operational costs. Correct alignment means the machine can run smoothly and efficiently, often reducing energy consumption significantly.

• • Reduced unplanned downtime and maintenance costs
    Equipment failure is expensive, not only in parts, but also lost production, labour, and emergency repair. Misalignment is often a root cause of unexpected breakdowns. By catching and correcting alignment issues early (or during installation), you avoid these disruptions, improving reliability and lowering long-term maintenance costs.

• • Extended equipment lifespan and reliability
    Regular, precise alignment helps machines operate as designed, which extends overall machinery life, boosts reliability, and protects your assets. For critical plant machinery, this reliability translates into smoother operations, fewer breakdowns, and better overall productivity.

• • Better safety and performance consistency
    Excessive vibration, mechanical stress, or unexpected failures not only cost money, they can pose safety risks. Proper alignment reduces those risks, creating a safer working environment. Moreover, correctly aligned machinery delivers more consistent performance, which supports production quality and reliability.

Laser Alignment vs Traditional Methods: Why it’s a better choice
Traditional alignment methods (for example, straight-edge and feeler gauge, or dial-indicator) are often subjective, slower, and less accurate.

By contrast, laser alignment:

• • Delivers precise, repeatable measurements, often within micrometre tolerances.
  • Minimises human error and guesswork, thanks to digital measurement and real-time feedback.
  • Enables quicker setup and correction, reducing machine downtime during maintenance or commissioning.
  • Detects and accounts for conditions like “soft foot” (uneven mounting) or thermal growth, factors that traditional methods may struggle with.

Because of these advantages, laser alignment has become the standard for industrial maintenance and reliability-focused programs.

Why choose TRS for your laser alignment needs
At TRS, we understand the critical role alignment plays in ensuring plant uptime, equipment longevity, and operational efficiency. Our laser alignment service offers:

• • High-precision alignment using advanced laser tools: ensuring shafts, couplings, and rotating equipment are aligned to OEM or industry-standard tolerances.

• • Experienced technicians and proven track record: we’ve aligned a wide variety of machinery across industries, delivering reliable, repeatable results.

• • Full lifecycle support beyond just alignment: we integrate alignment into a broader maintenance and monitoring program, covering mechanical and electrical condition monitoring, servicing, reinstallation, and re-alignment as needed.

• • Cost-effective, reliability-driven approach: alignment from TRS helps reduce unplanned downtime, prolong equipment life, and cut maintenance and energy costs over the long run.

Whether you’re commissioning new machinery or maintaining existing assets, including laser alignment in your maintenance schedule is a smart, proactive step.

Summary
Laser alignment is a precision technique for aligning rotating shafts in industrial machinery, ensuring the centrelines of coupled shafts are collinear and within tight tolerances. Compared with traditional methods, laser alignment delivers superior accuracy, repeatability, and speed, detecting even small misalignments that can lead to vibration, premature wear, energy waste, or catastrophic failure. Proper alignment reduces maintenance costs, extends equipment life, improves energy efficiency, minimizes downtime, and enhances safety and reliability. At TRS, we offer professional laser alignment services, backed by expertise, full lifecycle support, and a commitment to keeping your equipment running smoothly.