Introduction: Metal Putty Fixes Leaks
In large-scale chemical industries, even a small leak can lead to big losses. Production stops, safety risks increase, and maintenance costs rise. Atul Ltd, one of India’s leading chemical companies, faced a similar challenge when a leak developed in one of its process pipelines. The company needed an urgent solution that could fix the leak without stopping operations for long hours.
That’s where Shree Ram Sealing Engineers stepped in with their quick and reliable repair solution using Metal Putty. This case study explains how the problem was solved efficiently, ensuring safety, speed, and savings.
Founded in 1947 by industrialist Kasturbhai Lalbhai, Atul Ltd is among India’s most respected integrated chemical companies. Originally named Atul Products Ltd and later renamed Atul Ltd in 1996, the company produces over 900 products and 400 formulations. These products cater to two key business segments — Life Science Chemicals and Performance & Other Chemicals.
Atul Ltd supplies chemicals to more than 6,000 customers across 27 industries, both in India and abroad. The company also operates through subsidiaries in the USA, UK, China, Brazil, and the UAE, which shows its global presence.
In such a large and complex operation, continuous production is crucial. Every hour of downtime affects output, quality, and revenue. Therefore, leak management and equipment reliability are vital parts of Atul Ltd’s plant maintenance strategy.
During a regular inspection, Atul Ltd’s maintenance team discovered leaks in one of their process pipelines. The pipe was responsible for transferring a critical chemical used in production. Even a minor leak posed serious safety risks due to the nature of the chemical involved. If the leak wasn’t fixed immediately, it could have led to:
- Production downtime
- Chemical wastage
- Increased maintenance expenses
- Potential safety hazards for the workforce
However, stopping production to replace or weld the pipeline would have caused nearly two days of downtime, leading to heavy losses.
Atul Ltd needed a fast, safe, and reliable repair that could be completed without shutting down the plant. That’s when they contacted Shree Ram Sealing Engineers, a trusted service provider known for their On-Line Leak Sealing and industrial maintenance expertise.
Shree Ram Sealing Engineers is a professional service provider offering Online Leak Sealing Services, Cold Welding, Metal Stitching, and Transformer Repair Solutions across industries like power, chemical, sugar, and paper. Their team specializes in in-situ repairs — fixing leaks while the system remains operational.
For this project, they recommended Metal Putty, a proven industrial compound used for sealing and repairing leaks in metal pipelines, tanks, and machinery.
Metal Putty is a high-performance epoxy-based compound filled with metallic particles. When mixed and applied, it forms a strong, durable, and corrosion-resistant layer that bonds perfectly with metal surfaces.
It is widely used in chemical plants, oil refineries, and power industries for:
- Stopping active leaks
- Rebuilding damaged metal parts
- Restoring worn-out surfaces
- Strengthening weak joints
The major benefits of Metal Putty include:
- Quick setting time – Repairs can be completed in hours instead of days
- High strength – Once cured, it becomes as tough as metal
- Temperature and chemical resistance – Ideal for harsh industrial conditions
- Ease of use – No complex tools or high heat required
The repair at Atul Ltd’s plant was carried out on-site by trained engineers from Shree Ram Sealing Engineers. The goal was to seal the leak efficiently while ensuring complete safety. Here’s how the process was done:
- Inspection and Surface Preparation: The team first inspected the pipeline and confirmed the leak location. The affected area was then cleaned to remove oil, rust, and debris. Proper surface preparation ensured better bonding of the Metal Putty.
- Leak Sealing and Putty Application: A temporary clamp was installed to reduce the leak pressure. After that, the Metal Putty was mixed thoroughly and applied directly over the leak area. The putty was shaped and spread evenly to cover the damaged portion.
- Curing and Hardening: The applied Metal Putty was allowed to cure. Within a few hours, it hardened into a strong metal-like surface capable of withstanding pressure and temperature.
- Final Inspection: After curing, the engineers performed a thorough pressure test to confirm that the leak was completely sealed. The system passed the test successfully, and normal operations continued smoothly.
The use of Metal Putty proved to be a fast and cost-effective solution for Atul Ltd.
Key Outcomes:
- Zero Downtime: The entire repair was completed without shutting down the system, saving around 48 hours of potential downtime.
- Improved Safety: The leak was sealed completely, reducing exposure risks and improving workplace safety.
- Cost Savings: The plant avoided the high costs of pipe replacement and production loss. Maintenance expenses were reduced by nearly 40% compared to conventional methods.
- Durable Solution: Even after months of operation, the repaired section remains leak-free and strong, proving the long-lasting performance of Metal Putty.
Atul Ltd’s maintenance team appreciated the quick response and professional execution by Shree Ram Sealing Engineers. They highlighted that Metal Putty repairs helped them continue production safely while avoiding major interruptions.
The reliability and durability of the repair convinced Atul Ltd to adopt Metal Putty as part of their preventive maintenance strategy for future leak issues.
This case study shows how Metal Putty can be a game-changer for industries like chemicals, power, and oil & gas. Instead of stopping production or replacing entire components, companies can restore damaged metal parts quickly and safely using this innovative compound. For Atul Ltd, the solution not only saved valuable time and money but also reinforced their commitment to safety and operational efficiency. Shree Ram Sealing Engineers continues to provide such effective repair services across India, helping industries stay leak-free and productive. If your plant faces similar challenges with metal leaks, Metal Putty could be the right solution — fast, strong, and reliable.
