CASE STUDIES

Manufacturing & Industries

Metlonics Saves ₹5.21L Monthly with Pune Gas

Executive Summary

Metlonics Industries Private Limited, a Punjab-based metal fabrication manufacturer, was experiencing rising fuel costs and operational inefficiencies due to its dependence on High-Speed Diesel.

Pune Gas partnered with Metlonics to transition its fabrication plant to LPG, delivering significant cost savings, improved efficiency, cleaner operations, and a rapid payback period. The conversion enabled a more streamlined and reliable fuel infrastructure while reducing operational complexities.

Key Stats

Efficiency Improvement
0 %
Annual Cost Savings
0 Lakhs/Year
Payback Period
0 Months

Before (High-Speed Diesel)

Monthly
  • High and volatile fuel costs
  • Thermal efficiency: ~85%
  • Fuel handling losses and spillage
  • High maintenance due to soot and carbon deposits
  • Dependence on pumping and pre-heating systems

After (LPG System by Pune Gas)

Monthly
  • Monthly cost savings: ₹5.21 Lakhs
  • Thermal efficiency improved to ~92% (↑ 7% improvement)
  • Cleaner combustion with no soot or carbon buildup
  • Elimination of pumping and pre-heating systems
  • Safer and simplified fuel handling

Client Overview

Metlonics Industries Private Limited, founded in 1969, is a family-owned manufacturing enterprise specialising in metal fabricated products for infrastructure, automotive, and agricultural sectors. With decades of experience, the company focuses on operational reliability, efficiency, and cost optimisation.

The Challenge

Diesel-based fabrication operations created multiple operational constraints:

  • High and fluctuating fuel costs 
  • Fuel handling losses and spillage 
  • Increased maintenance due to soot and carbon deposits 
  • Dependence on pumping and pre-heating systems 

The setup added complexity, reduced efficiency, and increased operational risk.

The Solution

Pune Gas implemented a customised LPG conversion solution tailored for fabrication operations.

The solution delivered:

  • Complete transition from diesel to clean LPG 
  • Elimination of pumping and pre-heating systems 
  • Higher calorific efficiency with cleaner combustion 
  • Simplified and safer fuel handling 

The project was executed during the Covid-19 period with strict adherence to safety and engineering standards.

Measured Savings and Operational Gains

  • Fuel Cost Reduction
    Savings of ₹5.21 Lakhs per month, significantly lowering operating expenses

  • Efficiency Improvement
    Thermal efficiency increased from ~85% to ~92%

  • Cleaner Operations
    Complete elimination of soot and carbon emissions

  • Operational Reliability
    Zero-leakage LPG installation ensuring safe and stable operations

Financial Outcome

  • Total investment: ₹15 Lakhs 
  • Monthly savings: ₹5.21 Lakhs 
  • Payback period: ~3 months 

The rapid payback reinforces LPG as a financially superior and operationally efficient fuel choice.

Execution

The project was executed seamlessly during the Covid-19 period, ensuring safe installation, precise engineering, and uninterrupted plant operations.

Client Testimonial

Mr. Gagan Tur
Director, Metlonics Industries Private Limited

“After experiencing savings at our powder coating plant, we decided to convert our fabrication plant to LPG as well. Pune Gas delivered the project seamlessly, even during the Covid-19 period. The installation recorded zero leakages, and the support was excellent.”

Conclusion

By transitioning from diesel to LPG, Metlonics Industries Private Limited achieved substantial cost savings, improved efficiency, and cleaner operations. Pune Gas delivered a safe, reliable, and high-impact fuel conversion solution with an exceptionally fast return on investment.