Performance Proof
Case
Studies.
Real results from real plants. See how Avani Group formulations deliver measurable improvements in uptime, cost, and equipment life.
40%AVG DOWNTIME CUTAcross cement clients
3×DRAIN EXTENSIONSynthetic oil programs
₹12Cr+SAVINGS DELIVEREDLast 24 months
99.2%UPTIME ACHIEVEDPower generation
Featured Results
Client Success Stories
Cement
40%
Downtime Cut
40% Downtime Reduction at Major Cement Plant
High-temp kiln chain lubricant eliminated unplanned shutdowns across 3 production lines.
A leading cement manufacturer in Gujarat was experiencing frequent unplanned shutdowns due to carbon buildup on kiln chain links. Avani Group's High-Temperature Chain Lubricant (HTCL) eliminated carbonization, extended chain life by 3×, and reduced maintenance interventions from weekly to quarterly.
Key Results
- Unplanned kiln stops reduced from 12/year to 4/year
- Chain replacement interval extended from 8 months to 24 months
- Annual maintenance cost savings of ₹1.2 crore
- Production uptime improved from 91% to 96.5%
High-Temp Chain Lubricant HT-280Open Gear Compound OG-4600
Steel
3×
Drain Extension
3× Gear Oil Drain Interval in Rolling Mill
Synthetic PAO gear oil extended drain intervals from 2,000 to 6,000 hours.
A steel rolling mill in Maharashtra was changing gear oil every 2,000 hours due to oxidation and viscosity breakdown. Switching to Avani Group's Synthetic PAO Gear Oil 220 extended the drain interval to 6,000 hours while maintaining FZG 12+ load stage performance. Oil analysis confirmed minimal oxidation and stable viscosity throughout the extended interval.
Key Results
- Oil drain interval: 2,000 → 6,000 hours
- Annual lubricant consumption reduced by 65%
- Gearbox temperature reduced by 8°C average
- No micropitting observed after 18 months continuous operation
Synthetic PAO Gear Oil 220Calcium Sulfonate Complex Grease CS-2
Mining
₹2.8Cr
Cost Saved
₹2.8Cr Saved on Wire Rope Replacements
Penetrating wire rope lubricant extended rope life by 2.5× across 8 mines.
An iron ore mining operation in Odisha was replacing wire ropes on hoists and draglines every 14 months due to internal corrosion and external wear. Avani Group's Penetrating Wire Rope Lubricant (PWRL) displaced moisture, protected core strands, and reduced surface friction — extending replacement cycles to 36 months.
Key Results
- Wire rope replacement cycle: 14 → 36 months
- Internal corrosion incidents reduced by 90%
- Surface wear rate decreased by 45%
- Cumulative savings of ₹2.8 crore over 3 years
Penetrating Wire Rope Lubricant PWRLOpen Gear Compound OG-3200
Power Generation
99.2%
Uptime Achieved
99.2% Uptime at Thermal Power Station
Turbine oil and transformer fluid program maintained reliability across 4 units.
A 1,320 MW thermal power plant in Madhya Pradesh faced turbine oil degradation and varnish formation causing trip risks. Avani Group's Turbine Oil TU-46 with advanced antioxidant package eliminated varnish, maintained RPVOT >2,000 minutes, and supported 99.2% unit availability over 24 months.
Key Results
- Unit availability improved from 96.8% to 99.2%
- Varnish-related trips: 6/year → 0/year
- Oil drain interval extended from 8,000 to 15,000 hours
- Oil analysis costs reduced by 30% with predictive monitoring
Turbine Oil TU-46Transformer Oil TI-30
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