Srinivasa Edifice Pvt Ltd. achieves 25% increase in production with Metso Life Cycle Services

25% increase in production and reduced cost of operations with Metso Life Cycle Services

Srinivasa Edifice Pvt Ltd has been able to focus more on their core business and leave the crushing challenges to the experts. In addition to this, after experiencing significant cost savings and enhanced production from their initial Metso plant, SEPL has placed an order for an additional five Metso plants, all to be supported with Life Cycle Services contracts to better support their varied projects spread across the southern region of India.

SEPL has gradually started expanding its foothold in the industry and has been awarded prestigious projects by the authorities. SEPL was not only able to deliver on or before the project deadlines, but also deliver with consistent product quality. With their business growing, SEPL wanted a partner who could take care of their production targets but also let them concentrate on their core business, i.e. construction of railway lines and roads.

“We have been using Metso plants since 2014. Initially, we used to run them ourselves. We had seen other big players in the industry offloading their crushing business to Metso. We also thought it was better to go ahead with an Annual Maintenance Contract (AMC) or LCS from Metso for our comfort and growth. So we not only gave our existing plant to Metso under an LCS agreement, we also started replacing our existing competitor plants with Metso plants, which would give us the LCS advantage, shares Mr. YV Krishna Mohan, Managing Director, Srinivasa Edifice Pvt Ltd. He added, “We planned to have plants in different states across the country, such as in West Bengal, Jharkhand, Orissa and Tamil Nadu. Hence, going with Metso would be even more beneficial for us, as Metso’s wide service support network across India could help us in running the plants efficiently. This was a big advantage for us, and it gave us the comfort we needed from a partner.”

“Srinivasa Edifice Pvt Ltd. has been involved in the construction business for more than three decades. They work on railway and road construction and their plant is basically a wide-variety multiple product plant. As SEPL wanted maximization of both railway ballast (40-60 mm) and aggregates (0-20 mm) for their national highway project, Metso provided SEPL with a fully automated mobile crushing plant. The two-stage Nordwheeler plant consists of a Nordberg® C106™ jaw crusher in the primary stage and a Nordberg® GP220™ cone crusher in the secondary stage. The cone crusher has extra-coarse large setting (LS) liners with a variety of settings, from small to extra-large, in order to maximize the production of aggregates and railway ballast from the same plant,” explains Mr. Niraj Srivastava, Vice President, Technical Support, Metso India.

With the support of the LCS contract, SEPL was able to produce 3000 tons of aggregates on average from one plant, irrespective of the designated material sizes. Whether there was a demand for ballast for railways or for aggregates for their road projects, it was easily met with the same plant without additional hassles. For the LCS support, a service engineer from Metso is deployed and is available on site and when there is a need. Maintenance planning and spare parts planning are easily handled by the service engineer. Training the manpower on how to run the plant effectively is also provided. This has enabled SEPL to work safely without loss of man-hours and to deliver a good quality end-product.

Mr. YV Krishna Mohan notes, “We are achieving, on average, 3,000 tons of production per day from one plant, when the plant is running for 13-15 hours, irrespective of the size. From this total, 50-60% is our self-consumption for our existing projects and the rest is being sold outside. With Metso, we can achieve the production we desire. Breakdown days have been minimized and the equipment is delivering good results – it is a huge cost saving for us. The shape and quality of material from the Metso plants are better and the volume we are getting from the Metso cone crusher is much more than with any other crusher.”

Automation and service support play a vital role in managing multiple plants

Automation plays a vital role in managing and maintaining the plant remotely, and it helps to provide additional cost savings. SEPL manages 16 plants across India, so keeping up the production, effectively planning for the spares and wears for each plant, and collecting and analyzing production and plant data was becoming a tough task. With Metso automation and responsive service support, all these hassles were handled smoothly and SEPL was able to save costs by managing all plants remotely.

“Thanks to automation, we are witnessing cost savings on electricity and diesel, as there is no idle running of the plant. The feeding is managed automatically and efficiently for both the jaw and cone crusher, and monitoring is done as per sequence through regular feed from the automated systems. With no idle running of the plant, the power consumption has decreased, as both the jaw and cone crusher are interlinked and feeding is done as per the crushing cycle only,” shares Mr. Mohan. He adds, “This invariably increases production for us and generates costs savings. Even if we are not present on the site, we are able to check the production and downtime data, and we can even analyze the reasons for such downtime. The system also informs us well in advance when maintenance is required and when we need to replace parts. This is undoubtedly the best advantage one can get using automation via digital mediums.”

Metso automation provides access to various views, including monthly data reports and monthly cost analysis of the plant. Using these reports, SEPL can effectively plan inventory and manage multiple plants from one location.

More Metso plants with LCS

Citing huge benefits, like cost savings and increased production, SEPL plans to expand its fleet with Metso plants only. Placing an order for five Metso plants with LCS was a well-thought-out plan from the company’s top officials. Mr. Jayadev Yelamanchi, Director, Srinivasa Edifice Pvt Ltd., shares, “We are pretty happy with the AMC (LCS) services offered by Metso, as we are able to concentrate more on our core business. In a recent six-month period, we bought five Nordwheeler plants with AMC, from Metso. With the addition of these five plants to our fleet of 16 plants, we are able to crush more than 50,000 tons of aggregates per month, on average. Apart from the AMC service, we are delighted that Metso delivered and installed these five plants in no time, sensing our urgent requirement. They were also able to design special liners for us, which solved our need for multiple products from one plant.”

With SEPL’s clear vision, the aggregates and railway ballast requirements will remain high in the years to come. Hence, SEPL is planning to supply aggregates and railway ballast to all the major players in the industry while also working on other projects. From INR 300 crores (EUR 37.5 M) in the last year, SEPL is expected to touch INR 700 crores (EUR 87.5 M) in the current year and is expecting to reach INR 1500 crores (EUR 187.5 M) in the next five years.

“With Metso and its PAN India service reach, we can plan to extend our reach into more states and expand our business. We plan to replace our existing competitor plants with Metso plants. Also, our endeavor is to add five new Metso plants each year and have a long-lasting relationship with Metso,” Mr. Mohan shares.

About SEPL: Srinivasa Edifice Pvt Ltd was registered in 1984. From the year 2000 onwards, it has gradually increased its foothold and is now doing turnover of INR 300 Crores (EUR 38 million) and has orders in hand worth INR 750 Crores (EUR 95 million). SEPL is a major supplier to South Central Railways, Vijaywada Depot, KCC Depot, Manubolu Depot, Marripalem and Simhachalam Depot in Vizag.