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Mining Fleet Reliability

Fuel-related breakdowns reduced in mining excavators

A mining contractor in South Kalimantan was experiencing frequent fuel-related breakdowns across its fleet. The company started with a limited trial on two excavators before deciding whether to expand the program across the site.

Discuss fleet breakdowns → See the bottle test
CustomerSouth Kalimantan mining contractor
ApplicationExcavator fleet fuel reliability
Limited trialTwo excavators
Result0 unscheduled filter changes
The Real Problem

Fuel instability caused 3 to 6 unscheduled filter changes per month

The contractor was seeing frequent breakdowns across its equipment fleet, with fuel filters becoming an unscheduled maintenance item instead of a predictable service part.

Before committing to a wider additive program, the company chose a limited trial on two excavators. The target was clear: reduce unscheduled filter changes and prove that the fuel itself could stay cleaner on site.

Before the additive program, the two excavators typically needed 3 to 6 unscheduled filter changes per month. With the additive, that dropped to 0 unscheduled filter changes during the limited trial.

Field Evidence

Bottle test showed sludge forming in untreated fuel within days

An accelerated test used fuel from the site. The sample without additive developed sludge and turned cloudy over a few days, while the treated sample remained clear.

Before bottle test with untreated fuel on the left and treated fuel on the right
Start of testSame fuel, two bottlesLeft without additive, right with additive at the start of the experiment.
After bottle test with untreated fuel cloudy and treated fuel clear
End of testSludge formed without additiveThe untreated bottle became cloudy with sludge, while the treated bottle stayed clear.
3 to 6Monthly unscheduled filter changes before trial
0Unscheduled filter changes with additive
2Excavators in limited trial
50%Fuel-related breakdown reduction in full-site trial
Why It Matters

Unscheduled filter changes cost more than the filter itself

01

Breakdowns disrupt production

Every unplanned stoppage takes equipment away from productive work and forces maintenance teams to react.

02

Filter changes become unpredictable

When filters plug unexpectedly, the maintenance schedule no longer reflects the real operating risk.

03

Sludge points to fuel condition

The bottle test showed sludge formation in untreated fuel, linking the field issue to fuel stability and cleanliness.

04

Small trials need clear proof

A limited excavator trial gave the contractor enough evidence to decide on a wider site program.

Inneron Solution

Inneron trialed the additive on 2 excavators, then scaled site-wide

Inneron supported a controlled additive trial on two excavators, focusing on unscheduled filter changes and visible fuel stability evidence from site fuel.

The result was strong enough for the company to move from a limited trial to a full-site trial. By the end of that wider trial, fuel-related breakdowns were reduced by half.

Before Frequent filter problems The two excavators saw 3 to 6 unscheduled filter changes per month.
After Cleaner operating result The trial reached 0 unscheduled filter changes, then progressed to a full-site trial with fuel-related breakdowns halved.
What Changed

Fuel-related breakdowns dropped 50% in the full-site trial

The value was not only fewer filters. The trial showed cleaner fuel behavior, fewer reactive maintenance events, and a result strong enough to justify a wider site rollout.

See Turbio Heavy Duty →
No unscheduled filter changes in the limited trialThe two excavators moved from 3 to 6 unscheduled filter changes per month to 0.
Visible fuel stability proofUntreated fuel developed sludge quickly, while treated fuel stayed clear in the accelerated site-fuel test.
Full-site trial approvedThe contractor used the limited-trial result to move forward with a wider trial across the site.
Fuel-related breakdowns halvedAt the end of the full-site trial, the company experienced a 50% reduction in breakdowns due to fuel-related issues.
For Mining Contractors

Filter plugging and breakdowns across the fleet?

Inneron helps mining operators prove fuel additive performance first on a controlled trial, then scale it when the evidence is clear.

Review your fleet issue →