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Caltex slashes waste and downtime on a dragline and shovel fleet

Caltex slashes waste and downtime on a dragline and shovel fleet


A major coal mining operation asked Caltex to improve the lubricant usage and maintenance on their dragline and shovel fleet.


State-of-the art machine audits and onsite inspections quickly revealed a range of concerns including:

  • 30% of the fleet ceased production to fill on-board lube tanks
  • Draglines running out of product resulting in downtime
  • Machine inspections failed to rectify problems or optimise lubrication performance
  • Very basic lubricant consumption reports unseen by site personnel
  • No routine inspection reports sent to maintenance personnel
  • Inefficient and expensive product usage

Effective insights to find improvements
Caltex introduced enhanced hydrocarbon management, class leading specialty lubricants as well as proven maintenance and reporting practices. A custom KPI scoresheet quickly demonstrated how a better client/supplier experience can reduce costs, improve lubrication practices, increase plant availability and extend component life.

This program also involved:

  • The upskilling of local teams by Caltex specialists

  • Establishing baseline lubricant consumption rates

  • Introducing a state-of-the-art tablet reporting program

  • Improved assessments that can be analysed against baseline data 

  • The ability to compare like-for-like consumption across the fleet to help optimise, standardise and ultimately reduce overall lubricant spend

Moving ahead in performance and profitability
Since Caltex completed the trial and established a robust monitoring, test and maintenance program no premature failures have occurred.

This initiative is also driving significant savings in operational expenses.

If you would like to know more, please contact Allan Schloeffel, Business Development Manager, Mining at

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