Author:
Shri Sanjay Chowdhury,
Vice President & Business Head,
Protective Coating Division,
Berger Paints India Limited
In the dynamic world of industrial coatings, Berger Protecton stands as a trailblazer, consistently pushing the boundaries of innovation and excellence. This legacy of achievement reached new heights through a transformative collaboration with Titagarh Wagons, one of India’s premier freight wagon manufacturers. Together, they embarked on a remarkable journey to redefine productivity, enhance durability, and revolutionize railway manufacturing.
The challenges were formidable. Titagarh Wagons faced significant hurdles with traditional coating methods, from prolonged drying times and high labour costs to issues with the durability and quality of their wagons. The stakes were high, as the company undertook the mammoth task of manufacturing 19,000 BCNA wagons for a project valued at approximately ₹670 crores. At the heart of this initiative lay the pressing need to overcome bottlenecks that had capped production at a mere 5-6 wagons per day. It was at this critical juncture that Berger Protecton stepped in, determined to transform the scenario.
Berger Protecton’s intervention began with a meticulous trial run. Over four days, the company’s R&D and Sales teams collaborated closely with Titagarh Wagons to assess the challenges and fine-tune solutions. Armed with insights from this trial, they introduced a groundbreaking protective coating system tailored specifically for the BCNA wagons. The results were nothing short of revolutionary.
One of the most impactful innovations was the transition from a conventional 4-coat painting system to an efficient 2-coat system. This shift not only reduced labour costs but also streamlined the application process, dramatically improving efficiency. Berger Protecton’s Quick-Drying (QD) technology further enhanced the painting cycle, slashing it from an arduous 24-25 hours to an astonishing 7-8 hours. The transformation was palpable, as the once-sluggish production line roared to life. Also, with airless spray technology huge reduction in transfer loss was established. The impact of these innovations rippled through every aspect of Titagarh Wagons’ operations. Daily production soared to an impressive 20-25 wagons, a staggering leap from the initial 5-6 wagons per day. The wagons themselves, now fortified with Berger Protecton’s advanced coatings, boasted superior resistance to corrosion, abrasion, and harsh weather conditions. Maintenance costs plummeted, and the wagons’ extended lifespan set a new benchmark for durability in the industry. Behind these remarkable outcomes was a deep commitment to empowering the workforce.
Berger Protecton provided comprehensive technical training to Titagarh’s painters, equipping them with the skills needed to ensure flawless application of the new coating system. This hands-on approach not only elevated the quality of the finished wagons but also instilled a culture of excellence and innovation within the team. The skill training resulted in 10-15% reduction on consumption. As the collaboration progressed, it became clear that this was more than just a business partnership; it was a testament to what could be achieved through shared vision and determination. Berger Protecton’s unwavering dedication to quality and customer-centric solutions shone through at every stage, from initial trials to the triumphant realization of the project’s goals.
Today, the story of Berger Protecton and Titagarh Wagons serves as a beacon of inspiration. It is a tale of how innovation and collaboration can overcome the most daunting challenges, setting new standards for efficiency and excellence. By seamlessly merging cutting-edge technology with practical application, Berger Protecton has not only elevated the efficiency of railway manufacturing but has also redefined what is possible in the industry. Berger’s innovating technology has effectively coated over 2500 coaches and wagons in past 7 years.
This partnership—a perfect blend of expertise, vision, and execution—will undoubtedly be remembered as a milestone in the annals of industrial manufacturing. It exemplifies the transformative power of strategic collaboration and serves as a model for future endeavours in the quest for progress and excellence.
In conclusion, the collaboration between Berger Protecton and Titagarh Wagons embodies the synergy of innovation, efficiency, and excellence. Collaboration, Communication, and Co-Creation were at the heart of this transformative partnership, driving the development of advanced coating technologies and streamlined processes. Commitment to quality and Courage to innovate ensured that challenges were not only addressed but turned into opportunities for growth.
With a focus on Development, Delivery, and Customer Delight, the project set new standards in productivity and durability, fostering sustainable success and client satisfaction. Empowered by Energy, Efficiency, and Excellence, Berger Protecton and Titagarh Wagons unlocked unprecedented potential, revolutionizing railway manufacturing and enhancing operational outcomes. Together, these principles exemplify a holistic approach to progress, inspiring a future defined by shared success and unparalleled value creation.
For more insights, please visit: www.bergerpaints.com
Product Expertise: Berger Paints India Limited | This Product Expertise is a part of our Latest Magazine: Subscribe to our Magazine Today!
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