Vedanta Aluminium accelerates operational excellence with cutting-edge Machine Learning and AI technologies

THEBUSINESSBYTES BUREAU

JHARSUGUDA, NOVEMBER 12, 2025

Vedanta Aluminium, India’s largest aluminium producer, is harnessing the rapid advancements in artificial intelligence (AI) and machine learning to implement groundbreaking technologies at its mega aluminium plant in Jharsuguda, Odisha. These Industry 4.0 innovations are driving new benchmarks in safer, more sustainable, and highly efficient operations at the world’s largest aluminium smelter.

In collaboration with Infinite Uptime, a leader in predictive maintenance and plant reliability solutions, Vedanta Aluminium has launched a transformative digital initiative aimed at revolutionizing plant processes. By integrating dynamic AI-driven insights, the initiative optimizes maintenance, enhances energy efficiency, and promotes operational excellence. The project involves the deployment of IoT-based sensors, which are integrated with AI analytics to monitor over 2,000 critical equipment points across 16 operational zones. These zones cover nearly 600 machines and pieces of equipment, including those in hard-to-access areas, significantly improving safety and boosting overall operational efficiency.

The IoT sensors capture vital real-time data, such as triaxial vibrations, temperature, total acceleration, and other critical parameters. This data allows for the early detection of potential faults, enabling maintenance teams to act proactively. Common issues such as misalignment, bearing wear, gear malfunctions, and electrical irregularities are automatically identified, with immediate alerts and actionable recommendations sent to the relevant teams. The initiative follows a structured Plan-Do-Check-Act (PDCA) methodology, ensuring systematic implementation and continuous improvement. Since its deployment, the system has successfully averted critical machinery failures and reduced unplanned downtime.

Speaking on the collaboration, C Chandru, CEO of Vedanta Jharsuguda, commented, “Our collaboration with Infinite Uptime is a testament to how digital and AI-driven technologies can reshape industrial operations in a rapidly evolving world. This initiative empowers our teams with real-time insights, strengthens reliability, and reinforces our commitment to safe, sustainable, and world-class manufacturing. We are determined to scale this initiative and explore more avenues for integrating technology to build operations that are second to none.”

Raunak Bhinge, CEO of Infinite Uptime, added, “Partnering with Vedanta Aluminium to deploy our AI-powered predictive maintenance solutions at the Jharsuguda plant underscores the transformative potential of technology in modern industrial operations. Together, we are setting new benchmarks for efficiency, safety, and reliability.”

Looking ahead, Vedanta Aluminium plans to expand this initiative by incorporating additional technologies such as thermography, oil analysis, and centralized diagnostic platforms. This expansion exemplifies the company’s vision of driving operational excellence, sustainability, and long-term value creation at the Jharsuguda plant.

Moreover, Vedanta Aluminium has integrated Industrial Internet of Things (IIoT)-based devices into the stacks at its thermal power plants in Jharsuguda to further optimize emissions control. These advanced systems ensure precise operation of fabric filters, enhancing the capture of emissions directly at the source. Through the continued deployment of both emerging and established technologies, Vedanta aims to stay at the forefront of industrial innovation, ensuring its operations are future-proof and capable of delivering unmatched efficiency across all fronts.

Vedanta Aluminium, a division of Vedanta Limited, is India’s largest producer of aluminium, manufacturing more than half of the country’s aluminium output — 2.42 million tonnes in FY25. A leader in value-added aluminium products, Vedanta Aluminium serves critical industries and is ranked 2nd in the 2024 S&P Global Corporate Sustainability Assessment for the aluminium sector, reflecting its leadership in sustainable development practices. With its world-class aluminium smelters, alumina refinery, and power plants in India, the company is driving the future of aluminium as a key material for a greener, more sustainable tomorrow.