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Synthetic Lubricants: A smart investment

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Akhil Jha, Vice President Technical, Shell India Markets explains the need and benefits of Synthetic Lubricants.

India has strong demand for lubricants consumption with growing opportunities in the future. Lubricant technology is driven by evolution in equipment hardware design, legislation changes, emerging customer needs and market competitive considerations such as cost, return on investment etc. Different models of equipments will require different types of advance technology lubricants as stress factor will vary from model to model. The demand from OEMs and end customers for better quality lubricants leads to technology developments, especially in the area of Synthetic Lubricants. Shell being ?first to market? with many lubricant innovations and the company?s commitment to research and development reflects that it is well placed to introduce the next generation of world-leading lubricants.

Why Synthetic Lubricants:
Need of the hour:

  • Greater life-span
  • Better protection of components at varied temperatures
  • Better lubricity
  • Better oxidation and thermal stability
  • Extended oil drain intervals
  • Reduced energy consumption

Synthetic lubricants are becoming more popular and are increasingly used widely worldwide. Higher fuel costs, lower cycle times and stricter emission norms make OEMs, lubricant suppliers and end-users to find ways to improve lubricants performance to meet these emerging requirements.

Shell synthetic lubricants are formulated to provide component protection, fuel economy and long-life operation, faster cycle times for most of the equipment. The company has a wide portfolio of synthetic lubricants for automotive & industrial applications and our technical advisors work very closely with customers for offering solutions to their needs (see in the box) by using Shell synthetic lubricants.

The main objective to develop synthetic lubricants is to safeguard capital investment by protecting customer?s equipment from wear and corrosion even under the most severe conditions, whether it is application of Shell synthetic greases for protecting heavily loaded bearings in the high-temperature or wet conditions of plants/equipments or Shell synthetic gear oils for wind turbines operating in remote locations where equipment durability and reliability of operations are critical. The exceptional protection, long life and system efficiency offered by Synthetic Lubricants are proven to increase productivity in real applications helping increase the profitability of one?s business.

What is Synthetic Oil?
To explain it further, Synthetic oil is a lubricant consisting of chemical compounds that are artificially made (synthesized). Synthetic lubricants can be manufactured using chemically modified petroleum components rather than whole crude oil but can also be synthesized from other raw materials. Synthetic oil is used as a substitute for lubricant refined from petroleum when operating in extremes of temperature because in general, it provides superior mechanical and chemical properties than those found in traditional mineral oils. Synthetic oils have high viscosity index which means less change in viscosity with temperature. Therefore they adapt to perform better in hot and cold conditions by staying thin enough to flow in cold and thick enough to protect at high temperatures. Synthetic oil also has lower coefficient of friction which helps to maximize both volumetric and mechanical efficiencies in an application. Hence, Synthetic Lubricants are a smart investment.

Types of Synthetic Lubricants
The use of synthetic lubricants in various industrial and automotive applications is becoming more and more common considering the large advantages. The word ?synthetic? has nearly become synonymous with high quality or high performance. The selection of right type of synthetic oil is essential carefully considering the application and OEM recommendation. It depends on key criteria of selection, such as extended drain interval, component durability, energy efficiency, fuel economy, high loads, high temperatures etc. Other factors like OEM recommendations, Low temperature performance, volatility, bio degradability etc are also considered important.

There are many types of synthetic oils. Some of the most popular fluids are Poly Alfa Olefins (PAO), Polyisobutylenes (PIBs), esters, Polyalkylene glycols (PAGs), silicones, alkyl benzenes, alkylated napthalenes and fluorinated polyethers. Besides Poly Alfa Olefins, other synthetics are not compatible with conventional mineral oils. Hence extreme caution needs to be exercised.

Besides the above mentioned synthetic fluids, GTL (gas to Liquid) technology has been rapidly picking up, since its invention by German scientists Fischer and Tropsch. The process has three steps. The first is partial oxidation of hydrocarbon (natural gas) to hydrogen and carbon monoxide. This gas mixture is known as synthesis gas or syngas. The second stage involves catalytic polymerization of the syngas into heavier, largely paraffinic liquid (waxy) hydrocarbons. This is the Fischer-Tropsch reaction, the gas-to-liquids part. Stage three requires hydroisomerization of the waxy material to form cuts suitable for fuel and lube base stocks. These base stocks are expected to be very pure, free of sulfur and with excellent volatility and viscosity characteristics. Currently Shell has the largest capacity of GTL production globally with over 140,000 bbl/Day.

Shell offers a comprehensive range of synthetic lubricants for variety of Automotive and Industrial applications backed by thousands of OEM Approvals and demonstrated value records. Shell Lubricant technical advisors can assist customers to choose the most appropriate type of synthetic lubricant depending on the type of application.

Advantages of synthetic lubricants
One of the major advantages of synthetic oil over mineral-based motor oil is its greater lifespan. In most types of engines and under any driving conditions, synthetic oil has potentially less frequent recommended change intervals than traditional motor oil under similar circumstances. This is because synthetic motor oil is both slower to decompose chemically and less susceptible to evaporation over time. However, it is still likely to become contaminated eventually and a regular service schedule should still be observed, even if engine oil level readings are normal. Synthetic motor oil also has superior composition to that of mineral-based motor oil. Because its components are produced under chemically controlled conditions rather than through conventional refining natural process, synthetic oil is free of the impurities that comprise a significant percentage of the volume of most traditional motor oils. By being both more chemically stable and containing no undesirable impurities, synthetic oil causes fewer problems.

Shell Lubricants? Synthetic product range includes
Hydraulic fluids
Industrial gear oils
Turbine oil
Compressor oils
Greases
Synthetic lubricants can add value to customer operation in terms of energy efficiency and maintenance costs which can help to:

Reduce lubricant consumption with extended life products
Shell Rimula R6 range of heavy duty diesel engine oils are designed to have outstanding oxidation and shear stabilities. Resisting oxidation helps to extend oil-drain intervals. If one wants to lower lubrication costs and still keep vehicles on the road, one would need lubricants and greases that help to extend oil-drain intervals.

Deliver fuel savings with synthetic technology oils
Lower viscosity oils can help to reduce fuel consumption by reducing the energy loss caused by friction. However lower viscosity can lead to concerns about the oil?s ability to protect against wear. Shell?s synthetic oils are designed to deliver fuel savings and protect through the life of the oil.

Extend filter-cleaning intervals with low-SAPS products
Shell?s synthetic oils have a high viscosity index which means that the oils change less with temperature. They adapt to perform better in hot and cold conditions by staying thin enough to flow when cold and thick enough to protect at high temperatures. Synthetic-base oils also provide better protection in cold start than mineral oils with excellent low-temperature flow even at – 40?C.

Protection for your equipment
Shell synthetic lubricants can help to safeguard your capital investment by protecting your equipment from wear and corrosion even under the most severe conditions. Whether your compressors, gears, hydraulics or bearings operate at extremes of speed, load or temperature or in wet and contaminated conditions.

Long oil and grease life
Shell synthetic lubricants offer the longest life oils and greases in the Shell range. These products enable to extend oil-drain and greasing intervals. Extended lubricant life saves money by cutting maintenance costs and reducing product consumption. And hence Shell synthetic lubricants can help to increase productivity by enabling twelve times longer life to equipment, eliminating failures and it processes to operate more efficiently. They can even help to cut costs directly by reducing energy consumption.

Helps in reducing environmental foot print
As mentioned, Synthetic lubricants offer the longest life oils and greases. These products enable to extend oil-drain and greasing intervals with confidence that your equipment is being protected for the entire period. Extended lubricant life saves money by cutting maintenance costs and reducing product consumption. Using less oil and grease can also help to reduce environmental footprint and cut disposal costs.

Shell synthetic products far exceed industry lubricant-life standards. For instance, Shell Tellus S4 ME synthetic hydraulic fluid has an oil life over 10 times the minimum in industry-standard tests. And Shell Corena S4 R synthetic oil for rotary air compressors can deliver up to 8,000 hours? oil life (or about three years of factory operation compared with about 2,000 hours for more basic, conventional compressor oils.

Market demand for Synthetic Lubricants in India
The total demand for synthetic oil is mainly is in consumer segment and industrial sectors. In consumer segment, it is 100 % for high end cars and bikes and for standard cars and two wheelers, it is about 2-3%. Total demand of synthetic lubricants is about 10 million liters annually for consumer segments. The industrial sector synthetic oil demand is about 0.8-1% of total lubricant demands totaling synthetic requirement which is close to 8 million liters. Among Industrial sectors power sector is having a maximum demand for synthetic lubricants, especially for wind turbine, turbine governing system and gas turbine applications.

While it is estimated that the current consumption of synthetic lubricants is about 6 per cent of the global lubricants consumption, it is expected to be about 10 per cent by 2020.

As stated earlier, benefits of using synthetic oils for an application needs to be examined considering several factors such as duty cycle, operating condition, sump size etc.

Reduction in Total Cost of Ownership (TCO) should be the overall driver for recommending synthetic oils for an application.

Akhil Jha Vice President Technical, Shell India Markets
Synthetic oil is not only slower to decompose chemically it is also less susceptible to evaporation over time.

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Economy & Market

Power Build’s Core Gear Series

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A deep dive into Core Gear Series of products M, C, F and K, by Power Build, and how they represent precision in motion.

At the heart of every high-performance industrial system lies the need for robust, reliable, and efficient power transmission. Power Build answers this need with its flagship geared motor series: M, C, F and K. Each series is meticulously engineered to serve specific operational demands while maintaining the universal promise of durability, efficiency, and performance.

Series M – Helical Inline Geared Motors
Compact and powerful, the Series M delivers exceptional drive solutions for a broad range of applications. With power handling up to 160kW and torque capacity reaching 20,000 Nm, it is the trusted solution for industries requiring quiet operation, high efficiency, and space-saving design. Series M is available with multiple mounting and motor options, making it a versatile choice for manufacturers and OEMs globally.

Series C – Right Angled Heli-Worm Geared Motors
Combining the benefits of helical and worm gearing, the Series C is designed for right-angled power transmission. With gear ratios of up to 16,000:1 and torque capacities of up to 10,000 Nm, this series is optimal for applications demanding precision in compact spaces. Industries looking for a smooth, low-noise operation with maximum torque efficiency rely on Series C for dependable performance.

Series F – Parallel Shaft Mounted Geared Motors
Built for endurance in the most demanding environments, Series F is widely adopted in steel plants, hoists, cranes and heavy-duty conveyors. Offering torque up to 10,000 Nm and high gear ratios up to 20,000:1, this product features an integral torque arm and diverse output configurations to meet industry-specific challenges head-on.

Series K – Right Angle Helical Bevel Geared Motors
For industries seeking high efficiency and torque-heavy performance, Series K is the answer. This right-angled geared motor series delivers torque up to 50,000 Nm, making it a preferred choice in core infrastructure sectors such as cement, power, mining and material handling. Its flexibility in mounting and broad motor options offer engineers the freedom in design and reliability in execution.
Together, these four series reflect Power Build’s commitment to excellence in mechanical power transmission. From compact inline designs to robust right-angle drives, each geared motor is a result of decades of engineering innovation, customer-focused design and field-tested reliability. Whether the requirement is speed control, torque multiplication or space efficiency, Radicon’s Series M, C, F and K stand as trusted powerhouses for global industries.

http://www.powerbuild.in
Call: +919727719344

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Economy & Market

Conveyor belts are a vital link in the supply chain

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Kamlesh Jain, Managing Director, Elastocon, discusses how the brand delivers high-performance, customised conveyor belt solutions for demanding industries like cement, mining, and logistics, while embracing innovation, automation, and sustainability.

In today’s rapidly evolving industrial landscape, efficient material handling isn’t just a necessity—it’s a competitive advantage. As industries such as mining, cement, steel and logistics push for higher productivity, automation, and sustainability, the humble conveyor belt has taken on a mission-critical role. In this exclusive interview, Kamlesh Jain, Managing Director, Elastocon, discusses how the company is innovating for tougher terrains, smarter systems and a greener tomorrow.

Brief us about your company – in terms of its offerings, manufacturing facilities, and the key end-user industries it serves.
Elastocon, a flagship brand of the Royal Group, is a trusted name in the conveyor belt manufacturing industry. Under the brand name ELASTOCON, the company produces both open-end and endless belts, offering tailor-made solutions to some of the most demanding sectors such as cement, steel, power, mining, fertiliser, and logistics. Every belt is meticulously engineered—from fabric selection to material composition—to ensure optimal performance in tough working conditions. With advanced manufacturing facilities and strict quality protocols, Elastocon continues to deliver high-performance conveyor solutions designed for durability, safety, and efficiency.

How is the group addressing the needs for efficient material handling?
Efficient material handling is the backbone of any industrial operation. At Elastocon, our engineering philosophy revolves around creating belts that deliver consistent performance, long operational life, and minimal maintenance. We focus on key performance parameters such as tensile strength, abrasion resistance, tear strength, and low elongation at working tension. Our belts are designed to offer superior bonding between plies and covers, which directly impacts their life and reliability. We also support clients
with maintenance manuals and technical advice, helping them improve their system’s productivity and reduce downtime.

How critical are conveyor belts in ensuring seamless material handling?
Conveyor belts are a vital link in the supply chain across industries. In sectors like mining, cement, steel, and logistics, they facilitate the efficient movement of materials and help maintain uninterrupted production flows. At Elastocon, we recognise the crucial role of belts in minimising breakdowns and increasing plant uptime. Our belts are built to endure abrasive, high-temperature, or high-load environments. We also advocate proper system maintenance, including correct belt storage, jointing, roller alignment, and idler checks, to ensure smooth and centered belt movement, reducing operational interruptions.

What are the key market and demand drivers for the conveyor belt industry?
The growth of the conveyor belt industry is closely tied to infrastructure development, increased automation, and the push for higher operational efficiency. As industries strive to reduce labor dependency and improve productivity, there is a growing demand for advanced material handling systems. Customers today seek not just reliability, but also cost-effectiveness and technical superiority in the belts they choose. Enhanced product aesthetics and innovation in design are also becoming significant differentiators. These trends are pushing manufacturers to evolve continuously, and Elastocon is leading the way with customer-centric product development.

How does Elastocon address the diverse and evolving requirements of these sectors?
Our strength lies in offering a broad and technically advanced product portfolio that serves various industries. For general-purpose applications, our M24 and DINX/W grade belts offer excellent abrasion resistance, especially for RMHS and cement plants. For high-temperature operations, we provide HR and SHR T2 grade belts, as well as our flagship PYROCON and PYROKING belts, which can withstand extreme heat—up to 250°C continuous and even 400°C peak—thanks to advanced EPM polymers.
We also cater to sectors with specialised needs. For fire-prone environments like underground mining, we offer fire-resistant belts certified to IS 1891 Part V, ISO 340, and MSHA standards. Our OR-grade belts are designed for oil and chemical resistance, making them ideal for fertiliser and chemical industries. In high-moisture applications like food and agriculture, our MR-grade belts ensure optimal performance. This diverse range enables us to meet customer-specific challenges with precision and efficiency.

What core advantages does Elastocon offer that differentiate it from competitors?
Elastocon stands out due to its deep commitment to quality, innovation, and customer satisfaction. Every belt is customised to the client’s requirements, supported by a strong R&D foundation that keeps us aligned with global standards and trends. Our customer support doesn’t end at product delivery—we provide ongoing technical assistance and after-sales service that help clients maximise the value of their investments. Moreover, our focus on compliance and certifications ensures our belts meet stringent national and international safety and performance standards, giving customers added confidence.

How is Elastocon gearing up to meet its customers’ evolving needs?
We are conscious of the shift towards greener and smarter manufacturing practices. Elastocon is embracing sustainability by incorporating eco-friendly materials and energy-efficient manufacturing techniques. In parallel, we are developing belts that seamlessly integrate with automated systems and smart industrial platforms. Our vision is to make our products not just high-performing but also future-ready—aligned with global sustainability goals and compatible with emerging technologies in industrial automation and predictive maintenance.

What trends do you foresee shaping the future of the conveyor belt industry?
The conveyor belt industry is undergoing a significant transformation. As Industry 4.0 principles gain traction, we expect to see widespread adoption of smart belts equipped with sensors for real-time monitoring, diagnostics, and predictive maintenance. The demand for recyclable materials and sustainable designs will continue to grow. Furthermore, industry-specific customisation will increasingly replace standardisation, and belts will be expected to do more than just transport material—they will be integrated into intelligent production systems. Elastocon is already investing in these future-focused areas to stay ahead of the curve.

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Economy & Market

Impactful Branding

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Advertising or branding is never about driving sales. It’s about creating brand awareness and recall. It’s about conveying the core values of your brand to your consumers. In this context, why is branding important for cement companies? As far as the customers are concerned cement is simply cement. It is precisely for this reason that branding, marketing and advertising of cement becomes crucial. Since the customer is unable to differentiate between the shades of grey, the onus of creating this awareness is carried by the brands. That explains the heavy marketing budgets, celebrity-centric commercials, emotion-invoking taglines and campaigns enunciating the many benefits of their offerings.
Marketing strategies of cement companies have undergone gradual transformation owing to the change in consumer behaviour. While TV commercials are high on humour and emotions to establish a fast connect with the customer, social media campaigns are focussed more on capturing the consumer’s attention in an over-crowded virtual world. Branding for cement companies has become a holistic growth strategy with quantifiable results. This has made brands opt for a mix package of traditional and new-age tools, such as social media. However, the hero of every marketing communication is the message, which encapsulates the unique selling points of the product. That after all is crux of the matter here.
While cement companies are effectively using marketing tools to reach out to the consumers, they need to strengthen the four Cs of the branding process – Consumer, Cost, Communication and Convenience. Putting up the right message, at the right time and at the right place for the right kind of customer demographic is of utmost importance in the long run. It is precisely for this reason that regional players are likely to have an upper hand as they rely on local language and cultural references to drive home the point. But modern marketing and branding domain is exponentially growing and it would be an interesting exercise to tabulate and analyse its impact on branding for cement.

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