In July 2024, TAKRAF India secured four contracts for the overhaul and maintenance of Bucket-Wheel Excavators (BWEs). Among these, two involved a complete refurbishment of both mechanical and electrical systems of a 1,400-liter bucket-wheel excavator (BWE 1422). Originally commissioned in 1992 at NLCIL for overburden removal, BWE 1422 was successfully recommissioned on 18 July 2025 following an extensive revamp at the NLCIL Mine II overhaul yard.
NLCIL, established in 1956, is a Government of India enterprise and a leading producer of lignite and power. Recognized as a Navratna PSU, it enjoys enhanced financial autonomy. The company operates three open-pit mines at Neyveli, Tamil Nadu, with a combined capacity of 28.5 MTPA.
The bridge-type BWE, with a bucket capacity of 1,400 liters, has logged more than 150,000 operating hours over its 33-year service life. To extend its lifespan, NLCIL initiated a major upgrade, replacing essential structural and mechanical components. The refurbishment, entrusted to TAKRAF India, was executed over 12 months from design to commissioning.
The modernization included advanced features such as structural integrity assessments, PLC-based control systems, VVVF drives, an HMI interface, AFDS fire safety systems, and wireless communication—aligning with DMS safety standards and extending the equipment’s operational life by approximately 15 years.
The recommissioning ceremony of BWE 1422 was led by Prasanna Kumar Motupalli, Chairman and Managing Director of NLCIL, in the presence of Dr Suresh Chandra Suman (Director of Mines), Samir Swarup (Director of HR), M Venkatachalam (Director of Power), and R Rajagopalan (Managing Director of TAKRAF India), along with employees from both organizations.
“This is the third consecutive refurbishment project entrusted to us by NLCIL, reaffirming the strong partnership we share. Supported by TAKRAF Germany, our team is committed to delivering customized engineering solutions that meet critical project needs. We deeply value NLCIL’s trust and continued collaboration,” said Rajagopalan Ramanathan, Managing Director of TAKRAF India.
TAKRAF India is a leading engineering and service provider specializing in mining, bulk material handling, and mineral processing solutions. As a subsidiary of the global TAKRAF Group, the company delivers advanced technologies and customized services tailored to the requirements of India’s mining and power sectors.
With expertise in the design, supply, installation, and maintenance of large-scale equipment such as bucket-wheel excavators, conveyors, and crushing systems, TAKRAF India plays a key role in supporting the country’s energy and infrastructure industries. Backed by the technological strength of TAKRAF Germany and a strong local presence, the company focuses on innovation, safety, and sustainability, ensuring reliable and efficient solutions for its clients.
