BlendingCommissioned & Operating
Integrated Lubricant Blending & Grease Manufacturing Plant Middle East
PROJECT SNAPSHOT
LOCATION
Middle East
CAPACITY
Confidential
TECHNOLOGY
Blending
PLANT STATUS
Commissioned & Operating
BALAJI CONSULTANTS’ ROLE
Process Design • Detailed Engineering • Equipment Supply & Integration • Site Erection & Installation Supervision • Commissioning
THE CHALLENGE
The client required an integrated manufacturing facility capable of producing a broad range of finished automotive lubricants, industrial oils, lithium-based greases and calcium-based greases from a single site, with the flexibility to manufacture multiple product grades and formulations.
OUR SOLUTION
Balaji Consultants designed and delivered the complete plant as a multi-product manufacturing facility, combining a semi-automated lubricant blending section with separate lithium and calcium grease manufacturing lines and integrated storage, milling and filling systems. The project was executed in planned phases to allow early commencement of commercial lubricant production while the grease section was completed.
PROCESS CONFIGURATION
The lubricant blending section uses a semi-automated batching and recipe-control system for base-oil transfer, additive dosing, temperature monitoring, agitation and batch-record management producing motor oils, gear oils, hydraulic oils, ATF and other grades. The grease section provides separate manufacturing lines: lithium greases are produced in a pressure-rated saponification vessel with dehydration, cooling, additive incorporation and milling; calcium greases in a dedicated atmospheric vessel. Both grease types pass through finishing mills and homogenisation equipment before filling.
PROJECT OUTCOME
- Integrated multi-product plant commissioned and in commercial operation
- Lubricant blending section producing automotive and industrial grades
- Lithium grease production line commissioned
- Calcium grease production line commissioned
- Semi-automated batching and recipe control operational
- Phased commissioning allowed early commencement of commercial production
SCOPE OF WORK
- Process design, plant layout & P&IDs
- Lubricant blending system & semi-automated batching control
- Lithium & calcium grease processing system design
- Equipment procurement, fabrication & supply
- Site erection & installation supervision
- Pre-commissioning, lubricant blending trials & grease product trials
- Operator training & operational handover
PLANNING A NEW RE-REFINING PLANT OR REVAMPING AN EXISTING ONE?
Balaji Consultants develops process configurations around your feedstock, required product quality, existing infrastructure, capacity and project economics.
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