A Success Story in Crushing and Screening Optimization

Omsakthi Mines and Minerals, a leading supplier of aggregates based in Tamil Nadu, faced persistent challenges in maintaining consistent production, quality, and plant efficiency. In 2020, after 5,500 hours of plant operation. Propel stepped in , conducting a detailed health audit to diagnose issues of their plant facing multiple operational hurdles, affecting both output and profitability, and implement corrective strategies under our Operations Maintenance Contract (OMC).

Key Challenges

High downtime and unexpected breakdowns.
Shortage of skilled manpower for plant operations and maintenance.
Difficulties in spare parts inventory management and timely replacements.
Disruptions in production planning and quality control.
Inability to achieve desired output and product quality.
Inefficient utilization of plant capacity.
Inconsistent fund flow caused by sudden breakdowns and spare costs.

Propel’s Solutions

We conducted a detailed health audit and implemented a suite of solutions tailored to Omsakthi’s needs:

24x7 Support & Reliability: Continuous OMC support eliminated inventory concerns and ensured rapid response to issues with stipulated time.
Boosted Efficiency : Proactive OMC services enhanced plant performance and process 2X reliability.
High Plant Availability : Real-time monitoring helped to maintain the plant between 85-90% *.
Maximized ROI : Optimized equipment usage led to better returns and increased durability
Reduced Downtime : Onsite maintenance prevented production interruptions.
Cost Savings : Streamlined parts usage lowered operational expenses.
Extended Equipment Life: Regular preventive maintenance increased the longevity of critical assets.
Performance Guarantees : Monthly Performance Guarantee (PG) tests ensured consistent on-plant performance and end products quality.

Results Delivered

The partnership yielded measurable improvements:

Uptime increased by 10–15%*, consistently reaching 85–90%* plant productivity.
Significant reduction in idle time through better planning and preventive care.
No increase in fuel or power consumption despite higher operational output.
Improved throughput and product quality, often exceeding process targets.
Enhanced customer satisfaction, leading Omsakthi to install two additional plants under Propel’s OMC contracts.

Customer Testimonial

We are completely satisfied with the OMC services provided by Propel Industries. All three of our crusher plants are running with Propel’s equipment. If we weren’t happy with their service at our first crusher plant, we wouldn’t have entrusted them with two additional crusher plants. Choosing Propel again shows how much we trust their products and services.
-Omsakthi mines and minerals

A Success Story in Crushing and Screening Optimization