Metso Insights Case studies Aggregates Exceptionally high plant availability at PNC Infratech
Aggregates Mining
Jan 11, 2019

Exceptionally high plant availability at PNC Infratech

A decade long partnership between PNC Infratech and Metso paves the way for future growth. Focusing on its core business of road construction and opting for Metso’s Life Cycle Services (LCS) packages for the supply of aggregates has resulted in PNC winning multiple early completion bonuses.
A screening equipment being fed in a quarry with haul trucks at the back.

Managing 25 projects across eight states successfully

PNC Infratech Ltd, a major road and infrastructure company in India and a leading player in the industryhas witnessed steady growth in road construction for the last two decades. Managing 25 projects across eight states and having earned an early completion bonus on many of its projects has made PNC a trusted name when it comes to finishing projects on scheduleCompanies that are able to finish jobs on time and within budget are often positioned to win additional business – and with significant bonuses also on the line for completing projects ahead of schedule. Focusing on its core business of road construction and opting for Metso’s Life Cycle Services (LCS) packages for the supply of aggregates has resulted in PNC winning multiple early completion bonuses, one example of which is the bonus of EUR 7.5 million (Rs.58-60 crores) for completing the Agra-Lucknow expressway before schedule. 

Producing more and minimizing costs

Managing a fleet of more than 35 Metso crushers in action across 15 plants spread across states is no easy task. Ensuring a steady stream of aggregates production is key to keeping projects on track, but it must be balanced against operating costs. It is important to get the most out of the crushing and screening equipment while coordinating the maintenance and servicing of the equipment to keep the machines up and running. The challenge comes down to finding a partner who can guarantee optimal levels of equipment availability and aggregate production levels to meet high demands from its ongoing road projects while keeping operational and maintenance costs in check. After careful consideration, PNC opted for Metso Life Cycle Services contracts to manage their crushing equipment at multiple sites and to free them up to concentrate on their core business of road building. LCS contracts are set up as complete packages comprised of crushing and screening equipment, maintenance and inventory planning, a Computerized Maintenance Management System (CMMS), plant operation with production goals and a clear Cost-per-Ton commercial model. 

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Exceptionally high equipment availability helps PNC deliver 5.6 million tonnes of aggregate

Out of the 25 ongoing PNC projects, four are currently managed under LCS contracts and the company is planning to convert more projects to the LCS model, citing the noteworthy advantages from the arrangement. Under an LCS contract, PNC benefits by using only genuine Metso spare and wear parts to minimize downtime; it believes the technologically upgraded solutions from Metso have helped them over the years to produce more at minimized costs.  

“Increased equipment availability, a reduction in downtime, improved production efficiency, reduced operating costs without compromising health, safety and the environment are among the benefits of a Life Cycle Services contract from Metso,” shares Chakresh Jain, Managing Director, PNC Infratech Ltd. 

“PNC’s phenomenal growth in the last decade can be credited to its timely planning and optimum utilization of resources. With great leadership, PNC has trusted Metso for over a decade now, and the trust has grown to such a level that they are opting for more LCS contracts with Metso.  PNC’s first LCS contract was at Kabrai in Uttar Pradesh; the plant has produced more than 5.6 million tonnes of aggregates with high availability, delivering results beyond expectations,” divulges Pavan Seth, Vice President, Service Operations, Metso India. 

Increased equipment availability, a reduction in downtime, improved production efficiency, reduced operating costs without compromising health, safety and the environment are among the benefits of a Life Cycle Services contract from Metso.
Chakresh Jain, Managing Director, PNC Infratech Ltd.

Relying on teamwork to deliver on the largest projects

Working with different models, such as EPC (engineering, procurement and construction), DBFOT (design-build-finance-operate-transfer), OMT (operate-maintain-transfer), requires flexibility and partners you can count on. To date, PNC has succeeded under these multiple models and credits its trusted partners, like Metso, for the seamless execution of projects.  

“Fixing challenging deadlines and working in backward integration to achieve these has been our success mantra. As soon as we get an order, one of our team initiates movement of our equipment and sets up a camp on site, while, simultaneously, the other team works on land acquisition so that the project can be started immediately,” shares Jain. He added, “If we employ the right resources at the right time and at the right place, and if your plant availability is handled effectively, there is no reason why projects cannot be completed before time.” 


A man at a quarry handling the control buttons of mobile crushing equipment.

PNC has a range of Metso equipment, such as Nordwheelers as well as Lokotrack® plants, and mobilizing this equipment from one location to another has been effectively managed with the help of Metso’s expert team. Jain notes, “The expert Metso team not only offers guidance on how to operate the plant, it also chips in with its technologically advanced solutions which change the business environment for us. One of the biggest benefits of Metso is that its plants and spare parts are being manufactured at its world-class facility in Alwar, India. This availability of spares and wears is never an issue with Metso, and Metso has been providing us with unparalleled services from day one.” The first crushing plant installed in 2006 was a combination of a Metso NW105™ portable jaw crushing plant, Metso NW1100™ portable jaw crushing plant and Metso's B7150 crusher; the equipment is still in operation and crushing for PNC.

One of the recent projects PNC completed and delivered was the Agra-Lucknow expressway, which it managed to complete 90 days earlier than the deadline; PNC expects an early completion bonus of approximately EUR 7.5 million (Rs.58-60 crores). “This was only possible with immaculate planning on site and mobilization of resources. We only use genuine spare & wear parts, which enhances the life of our equipment and prevents any untimely shutdowns. With Metso’s expert team by our side, our plants are always up and running, and Metso’s services differentiates it from all the players in the market,” divulges Jain.

Metso has been a trusted partner to PNC for over 10 years. The first Metso plant commissioned for PNC was at Ratlam in 2006 –and it is still in action today. Other plants, at Nangal, Ghatauli and Kabrai, have produced over 4.1, 4.8 and 5.6 million tonnes, respectively. The Nangal and Kabrai plants are currently under a Life Cycle Services (LCS) contract with Metso and delivering optimum results with exceptionally high plant availability for PNC; this has convinced them to opt for more LCS contracts for their other sites.

A night time view on the PNC quarry in India.

PNC Infratech Ltd

Building roads, highways, runways, power transmission lines, and developing industrial towns, PNC Infratech Ltd. has been in the road business for almost three decades at the national and state level. It started its operations in 1989 with a small road project and became a private limited company in 1999 as it secured a number of larger projects. In 2001, PNC became a public limited company, executing some of the largest projects across India. For the first national highway project allocated to PNC in 1999, the Agra-Mumbai highway project (NH 3), the company earned a bonus from NHAI (National Highway Authority of India) for completing it ahead of schedule. PNC was one of the first companies awarded early completion bonuses, creating a benchmark in the industry.

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