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From High Costs to High Performance: 3X Life, ₹45 Lakhs Saved Annually

About the company

A leading industrial operation utilising excavators and loaders in challenging conditions (salt, bulk material, and dust) faced significant issues with their existing standard grease. This led to cake formation, frequent re-greasing (twice daily), pin failure, and costly replacements of Pin N Bushes. The company was incurring substantial annual costs, spending approximately Rs. 2,01,600/- per machine on grease, amounting to a total of Rs. 1,61,28,000/- for their 80 machines.

The Challenge

The Solution

We recommended a specialised, high-performance grease engineered for extended operation, Azure 2 Ultra PB. A controlled field trial was initiated, applying 1 kg of the new grease with a re-lubrication interval extended to 48 hours, gradually increasing the time between applications.

The Results

  • No cake formation and no noise were observed even after 50 hours of operation without re-greasing.
  • Re-greasing frequency dramatically improved from every 12 hours to every 36 hours.
  • Grease life tripled, reducing consumption by two-thirds.
  • Eliminated the need for Pin N Bush replacements, associated labour, and working hour losses.
  • Annual grease cost per machine decreased to Rs. 1,44,000/-.
  • Total annual savings of Rs. 45,08,000/- across all 80 machines, solely from reduced grease consumption.
  • The client approved the new grease for use in all 80 machines.

Testimonial