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Proactive Maintenance

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Gaurav Mathur, Director and Chief Executive, Global Technical Services, discusses the importance of an on-site oil testing laboratory within industrial plants for improved safety, extended equipment life and cost effectiveness in the manufacturing sector.

Oil condition monitoring can provide important information about the condition of the machine through oil analysis. Lubricant in any machine is like blood in the human body. Just as a blood test can help a doctor diagnose an illness and inform a treatment plan, similarly an oil analysis can provide an effective way to know the machine condition and inform it to take maintenance decisions.
Once the oil test laboratory is within the plant, the test reports are made available to the machine maintenance team within a timeline of 48 hours. Timely action helps reduce the expensive mechanical maintenance costs and improves machine life and productivity, leading to the plant’s profitability.
Normally, the oil testing laboratories are far away from the plant. They are mostly in a different city, and these laboratories provide test reports after 10 to 15 days. However, those reports are of no use in machine maintenance as mechanical damage starts to set in within 48 hours in any machine. Hence, it is important to have an on-site oil test laboratory within the plant.
Oil condition monitoring, covering moisture (water presence in the oil), particle contamination, wear debris analysis or loss of additives level, etc. are the parameters that clearly bring out any machine’s internal condition. This reporting leads to timely maintenance decisions by the mechanical team. These reports also help improve the reliability of the machine being tested.
Thus, an oil testing laboratory within the plant site is instrumental in greatly improving the value of machine life and reducing a major cost of mechanical maintenance. These improvements and cost reductions in turn lead to cost savings, profitability and enhance efficiency in manufacturing.

OIL ANALYSIS AT SITE LABORATORY
Oil analysis is an important activity used to check oil health, oil contamination, oil cleanliness level, and machine wear. Its main purpose is to verify that a lubricant in the machine is operating with the oil in good condition i.e. the oil is free from any contamination due to continued usage in the machine over a period of time.
An on-site oil testing laboratory helps to form a system for early detection of oil degradation, contamination, and machine wear. Early detection has several benefits that ensure a healthier environment for the employees and the machinery, such as improved safety, early detection and warning of machine degradation, and increased equipment availability and effectiveness.
Once the oil testing laboratory is established within the plant, thereafter, the next step is to prepare department-wise, machine-wise oil testing schedules. These schedules ensure that there is periodic oil testing and subsequent corrective measures can be taken by the mechanical team. This kind of reporting and availability of the
on-site laboratory leads to a more proactive mechanical maintenance.
Almost 82 per cent of wear-related failures are the direct result of particle contamination.
It is a well-known fact that lubricating oils in a machine never dies. Once the contaminants are removed and the oil cleaned to its original level, the oil can be made as good as ‘new’. Hence, a good oil filtration and accurate additives treatment at site assumes considerable importance in ‘oil conservation’ in the industry. By conducting the above activity about 40 per cent to 50 per cent conservation of the lubricant oil can be achieved.
Hence, having a site condition monitoring laboratory not only improves the life of the machines, it also reduces mechanical maintenance costs and can bring a large economic change in the cement manufacturing sector. Besides, oil can also be recycled to its original level. Thus, having an on-site oil testing laboratory is paramount important and profitable for all large industries.

Concrete

Adani Group To Set Up Cement Factory In Madhya Pradesh

Chief Minister Mohan Yadav inaugurates plant in Guna

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Adani Group (Adani) will set up a cement factory in Madhya Pradesh, the chief minister of the state announced after an inauguration ceremony in Guna. The chief minister, Mohan Yadav, described the occasion as a historic day for the state and said the project will strengthen industrial capacity. The event was presented as a milestone in efforts to broaden manufacturing and attract large-scale investment. Officials said the facility will add to regional production capability and support related industries.

State officials outlined that the plant will enhance supply chains for construction and infrastructure projects across the region. The company will bring technical expertise and logistical resources to the site, with government agencies coordinating approvals and land allocation. Local suppliers and service providers will benefit from increased demand, and training initiatives will be developed to build workforce readiness. Officials indicated that the project complements broader plans to modernise industrial clusters in the state.

The state administration said it has facilitated clearances and infrastructure support to accelerate implementation. Local officials have coordinated with the company to ensure connectivity and utilities are in place ahead of commissioning. The chief minister emphasised that collaboration between private investors and the government aims to create sustainable economic growth. Community outreach programmes will address local concerns and establish grievance mechanisms as construction proceeds.

Officials said the inauguration in Guna marks a new phase in the state industrial story and will serve as a reference for future investments. Administrators noted that close monitoring and periodic reviews will guide timely execution and adherence to environmental and safety norms. The government affirmed its commitment to facilitating responsible industrial expansion while ensuring benefits reach local communities. Stakeholders will continue discussions on supply chain integration and long term maintenance arrangements.

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Concrete

Railways Boost Cement Movement by 170 Per Cent and Eye Fly Ash

New container wagons cut costs and speed turnaround

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Indian Railways has recorded a 170 per cent rise in cement movement in the last four months after reforms launched in November to promote rail based bulk cement logistics. The Union Railway Minister, Ashwini Vaishnaw, reviewed the container sector reforms and their implementation and described the shift as improving plant to market efficiency. The reforms introduced customised bulk cement tank containers and a bulk cement terminal policy to support multimodal handling and door to door solutions.

The new system has simplified loading and unloading by enabling mechanised operations and by reducing package losses compared with bagged cement transport. Since cement can move directly from manufacturing centres to consumption centres in standardised tank containers compatible with Ready Mix Concrete machines, two stages of handling have been eliminated and material loss has been reduced. The standard shape of the containers facilitates faster turnaround and lowers logistics costs for suppliers and builders.

The improved freight turnaround is helping to lower the delivered cost of cement, which can ease pressure on housing costs for the poor and middle class and support affordable construction. The reform is said to be environment friendly as dust generation during material transfer has fallen and fuel consumption and emissions have reduced due to modal shift from road to rail. The Make in India tank containers are designed for seamless movement between train and trailer and to enable efficient door to door movement while cutting congestion on roads.

Building on the cement reforms, officials were urged to tap the fly ash transportation market to convert industrial waste into national wealth. The minister noted that nearly 300 million metric tonnes (mn t) of fly ash is produced in the country while only about 13 million t is transported by rail and asked officials to substantially increase Railways share to serve brick kilns, cement industries and construction sites. Wider utilisation of fly ash should reduce pollution, promote recycling and lower construction material costs while strengthening sustainable freight movement across infrastructure sectors.

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Concrete

Dalmia Bharat launches Weather 365 in East India

New water-repellent cement targets weather-resilient housing demand

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Dalmia Bharat Cement has launched Weather 365, a super-premium water-repellent cement brand for retail markets in West Bengal and Bihar. The product is designed to address rising demand for durable and weather-resistant construction materials in Eastern India.
Weather 365 offers protection against seepage, dampness and moisture damage, especially in regions exposed to heavy rainfall, humidity and changing weather cycles. The cement is suited for roofs, columns and foundations, and uses uniform water-repellent technology to reduce water penetration, steel corrosion, efflorescence and damp patches.
The company said the product will be available in water-resistant and tamper-proof BOPP packaging. It will also provide on-site technical support through engineering and technical services teams to guide customers on construction practices and long-term building performance.
Positioned in Dalmia Bharat Cement’s premium portfolio, Weather 365 targets homeowners, contractors and builders seeking stronger concrete, improved paint life and better structural durability. The launch supports the company’s strategy to expand premium construction solutions in key Eastern India markets.

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