Case Studies · One page · Eight mills
What we actually do, mill by mill. Every story on one page.
Each case captures real mill-house problem, the LAAPSA & Cenlub Systems intervention, and the operational outcome recorded by season-end. No long detail pages. No videos to load. Read all and see which story looks closest to your mill.
Most recent case studies
33% Consumption Reduction · Season one
Bhimashankar Cooperative · 5,000 TCD · Maharashtra
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Case 01 · Maharashtra
33% Consumption Reduction · Season one
Bhimashankar Cooperative · 5,000 TCD · Maharashtra
Challenge
- Bearing temperature spikes (50-60 deg.C) during peak crushing
- Due to this, unscheduled overnight stoppages
- Grease consumption 18 kg/day
- Frequent bearing changes
- Unable to increase the crushing rate
Solution
- CLS audit and DBA implementation
- Dose feeder under capacity
- Cenlub retrofit completed during off-season
- LAAPSA SugarPress BR 32000 used for full season
- Weekly remote monitoring
Outcome
- 33% lower lubricant consumption, (12 kg/per)
- Zero peak-season breakdowns
- Bearing temperature maintained within 10° of ambient temperature
- Repeat purchase approved
Case 02 · Uttar Pradesh
Zero PCB Notices · 2024–25
Dwarkesh Sugar Industries · 10,000 TCD · UP
Challenge
- CPCB Charter 2.0 compliance pressure
- Asphaltic oil entering effluent treatment plant
- High COD/BOD levels
- Environmental risk during crushing
Solution
- Journal bearings switched to LAAPSA SugarPress BR 32000
- Open gears converted to OG WP
- OECD biodegradability documentation submitted
- Compliance review completed pre-season
Outcome
- Lower ETP load
- COD/BOD levels reduced
- Compliance maintained through Charter 2.0 transition
- Zero PCB notices in 2024–25
- Improved environmental performance
- Oil skimmer removed
Case 03 · Karnataka
₹68 Lakh Cumulative Savings · 3 Seasons
Godavari Sugar Mills · 15,000 TCD · Karnataka
Challenge
- Annual bearing rebuild cycle
- High off-season repair expenditure
- Recurring downtime costs
- No improvement despite supplier changes
Solution
- Three-season pilot programme
- LAAPSA SugarPress BR 1000/ 32000 implementation
- Quarterly Cenlub audits
- Maintenance-team training
Outcome
- Reduced bearing rebuilds for three seasons
- ₹68 lakh cumulative savings
- Reduced downtime costs
- OG WP evaluation expanded
Nirani Sugars Limited · 15,000 TCD ·
Challenge
- Abnormal bearing temperature reaching 80–90°C
- Recurring bearing failures.
- Grease consumption as high as 55–60 kg/day.
- Crushing reduced
REASON
- Due to high temperature, the base oil viscosity drastically drops from 2500 cSt to 80–90 cSt.
- The grease becomes like oil and flows out.
- Hence, consumption is more and the additives do not stay on the bearing.
Solution
- Noted the Lubrication is not enough to the Main bearings.
- Changed the conventional dosefeeders to Modular dose feeders where the Main bearings gets adequate Lubrication
- Journal bearings switched to SugarPress BR 32000 Ultra High Viscosity Gel
- 20×+ higher viscosity than conventional grease base oil at 100°C, enabling lower consumption and supporting increased bearing life.
- Organic & synthetic hydrocarbon formulation — biodegradable and eco-friendly
- No toxic elements, reducing ETP and environmental burden while supporting worker-friendly lubrication
Outcome
- Consumption reduced from 55-60 kg/day to 30 litres/day
- ₹1,260/day direct saving
- ₹2.27 lakh projected saving over 180 days
- bearing temperature reduced by 4–5°C
- Crushing rate reached 15,000 TCD
- Improved bearing performance with reduced risk of recurrent failures
- Recommended for continued long-term use
₹68 Lakh Cumulative Savings · 3 Seasons
Challenge
- Abnormal bearing temperature reaching 80–90°C
- Recurring bearing failures.
- Grease consumption as high as 55–60 kg/day.
- Crushing reduced
REASON
- Due to high temperature, the base oil viscosity drastically drops from 2500 cSt to 80–90 cSt.
- The grease becomes like oil and flows out.
- Hence, consumption is more and the additives do not stay on the bearing.
Solution
- Noted the Lubrication is not enough to the Main bearings.
- Changed the conventional dosefeeders to Modular dose feeders where the Main bearings gets adequate Lubrication
- Journal bearings switched to SugarPress BR 32000 Ultra High Viscosity Gel
- 20×+ higher viscosity than conventional grease base oil at 100°C, enabling lower consumption and supporting increased bearing life.
- Organic & synthetic hydrocarbon formulation — biodegradable and eco-friendly
- No toxic elements, reducing ETP and environmental burden while supporting worker-friendly lubrication
Outcome
- Consumption reduced from 55-60 kg/day to 30 litres/day
- ₹1,260/day direct saving
- ₹2.27 lakh projected saving over 180 days
- bearing temperature reduced by 4–5°C
- Crushing rate reached 15,000 TCD
- Improved bearing performance with reduced risk of recurrent failures
- Recommended for continued long-term use
Case 04 · Uttar Pradesh
Stabilised Within 14 Days
SBEC Sugar · 5,000 TCD · UP
Challenge
- Mid-season bearing failure
- Production interruption during peak intake
- Previous synthetic-gel programme unsuccessful
- High operational risk
Solution
- Emergency conversion to LAAPSA SugarPress BR 32000
- Field team deployed within 48 hours
- CLS line re-pressurised
- New dose-feeders installed
Outcome
- Stable operation within 14 days
- Remaining season completed successfully
- No additional bearing failures
- Permanent adoption approved
Case 05 · Maharashtra
32% Consumption Reduction · First Season
Jayawant Sahakari Sakhar Karkhana · 2,500 TCD · Maharashtra
Challenge
- Concern over higher per-kg lubricant cost
- Smaller-mill economics questioned
- Board approval uncertainty
- Consumption-focused purchasing
Solution
- Per-day operating-cost analysis (completed DBA with CLS auditing)
- Mill consumption data reviewed
- Before-and-after baseline documented
- Trial programme agreed
Outcome
- 32% lower lubricant consumption
- Improved operating economics
- Successful performance at 2,500 TCD scale
- New peer reference for cooperatives
Case 06 · TAMIL NADU
Temperature Below 48°C All Season
Tamil Nadu Cooperative Sugar Mill · 3,000 TCD · Tamil Nadu
Challenge
- High ambient temperature and humidity
- Very high load on ETP/regular PCB warnings
- Rising bearing temperatures(around 70-80deg.C)
- Frequent recalibration concerns
Solution
- LAAPSA SugarPressBR 32000 deployed
- Completed CLS auditing and DBA
- Dose-feeder profile adjusted
- Service support provided for continuos monitoring of bearing temperature
- Technical monitoring throughout season
Outcome
- Bearing temperature remained below 48°C
- Zero load on ETP
- Bearing life extended
- The lubrication cost per day reduced to 25%
- No mid-season recalibration required
- Stable crushing-season performance
- Became regional reference case
Case 07 · Gujarat
4 → 0 Bearing Rebuilds Per Season
Sahakari Khand Udyog Mandal · 5,000 TCD · Gujarat
Challenge
- Average bearing temperature of 56°C
- Peak spikes reaching 70°C
- Four rebuilds per season
- Reliability issues affecting operations
Solution
- Long-term LAAPSA partnership
- Annual Cenlub audits
- Daily temperature logging
- Continuous product optimisation feedback
Outcome
- Average bearing temperature reduced to 42°C
- Peak temperature limited to 47°C
- Rebuilds reduced from four to zero
- Co-author of STAI 2014 paper
Case 08 · Punjab
ISO 22000 recertification cleared · mill house exemplar
Punjab Cooperative Sugar Mill · 4,500 TCD · Punjab
Challenge
- Mill-house cleanliness audit finding
- Bituminous oil residue on equipment
- Floor contamination concerns
- ISO 22000 recertification at risk
Solution
- Switched to LAAPSA SugarPress BR 1000/32000
- OGWP deployed on open gears
- Single pre-season changeover
- Operator handling protocol updated
Outcome
- 33% lower lubricant consumption, (12 kg/per)
- Zero peak-season breakdowns
- Bearing temperature maintained within 10° of ambient temperature
- Repeat purchase approved
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