5 Days of Production Saved 

One morning, a key production machine at a Utah-based manufacturer wouldn’t start. No warning. No workaround. Just a dead screen…and years of critical cut files trapped on a corrupted flash drive.

If they couldn’t recover those files, they were looking at 3 to 5 days of no production. That meant late orders, lost revenue, and long hours trying to rebuild complex data from scratch.

​​​​​​​They called Equinox.

This manufacturer relies on a specialty machine to cut product components with extreme precision. The system runs off a flash-based memory card. No traditional hard drive, no cloud sync. Just one card holding the operating system and all their cut files.

​​​​​​​After a brief power outage, the machine wouldn’t boot. Their backup OS card got the machine bootable, but it didn’t include any of the custom cut files to operate. Worse, there was no backup system in place for those files at all.

At that moment, everyone on the floor was waiting. A single corrupted flash card was holding up their entire production line.

The Equinox tech team brought the card back to our office and immediately began data recovery efforts. It wasn’t a typical hard drive. This was a flash-based memory card that stored both the operating system and years of custom cut files.

​​​​​​​We couldn’t just plug it in and hope. Here's what we did instead:
​​​​​​​

• Used a flash card reader and advanced software to manually mount the damaged card
• Recovered all custom production files, one by one, from the card’s corrupted structure
• Transferred the files to their internal server to give them secure, central access
• Set up a weekly USB-based backup routine (easy for their team to use)
• Worked with the machine manufacturer to get a fresh OS card, plus a backup

​​​​​​​In less than 24 hours, the files were saved, the machine was restored, and production was back online.

​​​​​​​
​​​​​​​Behind the scenes, it took late-night recovery work, hands-on coordination, and some creative thinking. But the real win wasn’t just solving the crisis. It was making sure they’d never be in that position again.

By the next morning, the shop floor was humming again. Machines were running, schedules were back on track, and no production time was lost.

What could have turned into a costly, multi-day recovery became just a brief bump in the road.
​​​​​​​

• 3–5 days of lost production avoided
• Critical files fully recovered
• A new backup process in place to prevent future risk

“If we hadn’t recovered that card, they would’ve lost nearly a week of production. Instead, they were back up and running in 24 hours.”
​​​​​​​— Equinox IT Services

This wasn’t a system we managed day-to-day. But when the call came, we acted fast and made sure the fix wasn’t just a one-time patch.

​​​​​​​Now, this manufacturer doesn’t have to hope their files are safe. They know they are