How an Industrial Gas Cylinder Manufacturer Innovated Faster and Better with a Robotics Startup

A case study on how Surya Shakti Vessels achieved operational and sustainability excellence with the help of Orangewood Labs—an AI-powered robotics startup

Startups as innovation partners are unmatched in their ability to develop and translate industrial technology to innovative operating capabilities and novel products at the lowest cost and fastest speed with agility and ingenuity. This enables industrial companies to overcome several barriers and blockers while increasing the odds of success at the lowest cost of innovation and zero financial risk, and achieving the fastest time-to-value with a shorter ROI combined with unparalleled technical support.

Surya Shakti Vessels Pvt. Ltd. (SSVPL), a prominent manufacturer of industrial gas cylinders, was grappling with the inefficiencies and inconsistencies of manual painting. Determined to overcome these challenges, SSVPL turned to robotic technology from Orangewood Labs, a portfolio startup of Forge that has established a Product Demo Lab (PDL) at one of the Forge stations, the SIPCOT Industrial Innovation Center (FORT. Hosur). This strategic adoption by SSVPL not only streamlined their processes but also marked a significant step towards achieving operational & sustainability excellence. Here is how SSVPL transformed their operation by leveraging technology.

Bottleneck in Manual Spraying

SSVPL based out of Faridabad, Haryana, India, faced limitations with their manual spray painting process. Producing over 3 million cylinders annually, SSVPL encountered issues like inconsistent paint application, material waste from both the initial application and touch-ups, and potential health risks for workers. These challenges hindered their ability to achieve the export-level quality and efficiency they desired. SSVPL’s reliance on manual spray painting resulted in a multitude of issues. The quality of the paint application varied greatly, leading to defects and the need for rework. This wasted valuable time and materials, impacting their bottom line. Additionally, the manual process exposed workers to potentially hazardous paint fumes, raising safety concerns.

Achieving Export-Level Quality through Robotic Automation

Orangewood Labs leads the charge in industrial automation with their innovative industrial hardware machines such as AI-powered robotic arms that seamlessly integrate into manufacturing operations. Orangewood Labs empower industrial companies to automate repetitive or complex tasks, significantly boosting efficiency and productivity.

By tackling hazardous tasks and adapting to evolving production environments, these robots enhance safety and flexibility. Ultimately, Orangewood Labs’ advancements pave the way for smart factories, optimizing processes and granting a competitive edge in the manufacturing landscape. Orangewood’s current applications address a variety of tasks, including Machine tending, palletization, visual inspection, surface coating, and many more.

To address the limitations of manual spray painting, SSVPL worked with Orangewood Labs to deploy Orangewood’s Robotic solution for spray painting. This 6-axis robot boasts advanced sensors and intuitive programming capabilities, allowing for customization to SSVPL’s specific needs. The implementation of the Orangewood’s robotic arm revolutionized the painting process. It standardised paint application, resulting in a superior finish and a dramatic reduction in material waste. Automation enabled precise control over paint application, ensuring consistent thickness and faster drying times.

Key Performance Indicators:

Benefits of Orangewood’s Robotic Solution

The Impact of the Orangewood’s Robotic Solution on SSVPL’s Production

Implementation of Orangewood’s robotic system has been transformative for SSVPL’s production process. Here’s a closer look at the significant improvements:

Operational Excellence:

• Increased Efficiency and Productivity: Automation has streamlined workflows, resulting in a notable increase in the daily production output of painted cylinders.
• Enhanced Decision-Making: Orangewood’s system generates valuable data-driven insights, empowering SSVPL to make more informed and strategic operational decisions. This translates to improved resource allocation and overall production planning.
• Improved Customer Satisfaction: Consistent high-quality finishes have led to a significant increase in customer trust and satisfaction. This has directly translated to a rise in export orders, solidifying SSVPL’s position in the global market.
• Reduced Costs: Automation has yielded a two-fold benefit on costs. Firstly, it has reduced labour requirements, leading to savings in manpower expenses. Secondly, the precise control over paint application minimizes waste, significantly impacting material consumption costs.
• Improved Quality Control: Real-time monitoring capabilities of Orangewood’s system allow for immediate adjustments during the painting process, dramatically reducing the need for manual touch-ups and rework. This ensures consistent quality across every cylinder produced.
• Enhanced Agility: The inherent flexibility of the Orangewood’s robotic arm allows for rapid adjustments to production needs. SSVPL can efficiently adapt to fluctuating market demands and ensure they remain competitive.

Sustainability Excellence:

• Reduced Environmental Impact: The Orangewood’s system has demonstrably reduced SSVPL’s environmental footprint. The optimized paint application minimizes waste, and the elimination of solvent-heavy manual processes reduces overall emissions. Additionally, the robotic system eliminates the need for human exposure to potentially hazardous painting environments.
• Increased Transparency: Implementing Orangewood’s system enhances visibility across the entire production chain. This allows for better data collection and analysis, promoting stricter compliance with environmental and safety regulations

Overall, the Orangewood’s robotic system has empowered SSVPL to achieve operational excellence and sustainability leadership. The significant improvements in efficiency, quality, cost savings, and environmental impact position SSVPL for continued growth and success in the global market. But most importantly, they’ve created a safer workplace for their employees. Surya Shakti Vessels have painted a brighter future, not just for their business, but for the environment and their workforce as well. Their story is a testament to the power of innovation and collaboration between industrial companies and startups.

At Forge, we fuel startup success by providing critical programmatic interventions across the entire lifecycle of industrial tech ventures — spanning innovation, production, industrialisation and commercialisation. Forge supports startups with strategic advisory, market access pathways, product acceleration & tech infrastructure, industrialisation & commercialisation partnerships, and investment pathways — all aimed at startups winning at every stage.

Forge’s Future Factories Launchpad initiative harnesses the innovation capacity within startups, academia (students & faculties), and research (scientists & technologists) to redefine manufacturing & value-chains through bold ideas and breakthrough solutions — unlocking value from operational, sustainability & business excellence in industrial companies. Know more about Forge here — https://www.forge-iv.co/