Vedanta Aluminium Accelerates Operational Excellence with Advanced Machine Learning-Based Technologies
12th November 2025
Jharsuguda, Odisha, 11th November 2025: Vedanta Aluminium, India’s largest aluminium producer, is leveraging rapid advancements in artificial intelligence and machine learning to deploy innovative, cutting-edge technologies at its mega aluminium plant in Jharsuguda, Odisha. At the world’s largest aluminium smelter, these Industry 4.0 technologies have been instrumental in enabling new benchmarks in safer, sustainable and more efficient operations.
In collaboration with Infinite Uptime, a leading provider of predictive maintenance and plant reliability solutions, Vedanta Aluminium has launched a transformational digital initiative to revolutionize plant processes through dynamic AI insights that offer optimized maintenance solutions, energy efficiency, and operational excellence. As part of this collaboration, IoT-based sensors have been integrated with AI-driven analytics to monitor over 2,000 critical equipment points across 16 operational zones. Encompassing nearly 600 machines and pieces of equipment in areas that are not easily accessible, this initiative is helping ensure increased operational safety and boosting efficiency across the plant.
The IoT sensors capture several essential parameters such as triaxial vibrations, temperature, total acceleration, and other key indicators in real-time, enabling early detection of potential faults. Common anomalies such as misalignment, bearing wear, gear issues, and electrical irregularities are automatically identified, with maintenance teams receiving instant alerts and actionable recommendations. The project follows a structured Plan-Do-Check-Act (PDCA) methodology to ensure systematic implementation and continuous improvement. Since deployment, it has successfully pre-empted critical machinery faults and unplanned downtime.
Mr. C Chandru, CEO, Vedanta Jharsuguda, said, “Our collaboration with Infinite Uptime demonstrates how digital and AI-based technologies can redefine industrial operations for a rapidly emerging world. This initiative equips our teams with real-time insights, improves reliability, and further reinforces our commitment to safe, sustainable, and world-class manufacturing. We are committed to scaling up this effort and exploring several more avenues to integrate technology and build world-class operations. ”
Mr. Raunak Bhinge, CEO, Infinite Uptime, added, “Partnering with Vedanta Aluminium to deploy our AI-powered high-accuracy prescriptive maintenance solutions at the company’s Jharsuguda plant highlights the transformative impact that technology can have in modern industrial operations. Together, we are setting new benchmarks for efficiency, safety, and reliability.”
Vedanta Aluminium plans to expand this initiative further by incorporating additional technologies such as thermography, oil analysis, and centralized diagnostic platforms. This program exemplifies the company’s vision of leveraging technology and innovation to drive operational excellence, sustainability, and long-term value creation at the Jharsuguda plant.
Beyond this, the company has also integrated Industrial Internet of Things (IIoT)-based devices into the stacks at its thermal power plants in Jharsuguda to optimise emissions control. These systems ensure that the fabric filters operate with precision, enhancing the ability to capture emissions at the source. With the continued deployment of both emerging and established technologies, it aims to remain at the forefront of industrial innovation, building operations are future-proof and capable of delivering unmatched and all-round efficiency.
Vedanta Aluminium, a business of Vedanta Limited, is India’s largest producer of aluminium, manufacturing more than half of India’s aluminium i.e., 2.42 million tonnes in FY25. It is a leader in value-added aluminium products that find critical applications in core industries. Vedanta Aluminium ranks 2nd in the S&P Global Corporate Sustainability Assessment 2024 world rankings for the aluminium industry, a reflection of its leading sustainable development practices. With its world-class aluminium smelters, alumina refinery and power plants in India, the company fulfils its mission of spurring emerging applications of aluminium as the ‘Metal of the Future’ for a greener tomorrow.
About Vedanta Limited:
Vedanta Limited, a subsidiary of Vedanta Resources Limited, is one of the world’s leading Oil & Gas and Metals company with significant operations in Oil & Gas, Zinc, Lead, Silver, Copper, Iron Ore, Steel, and Aluminium & Power across India, South Africa and Namibia. For two decades, Vedanta has been contributing significantly to nation building. Governance and sustainable development are at the core of Vedanta's strategy, with a strong focus on health, safety, and environment. Vedanta has put in place a comprehensive framework to be the ESG leader in the natural resources sector. Vedanta is committed to reducing carbon emissions to zero by 2050 or sooner and has pledged $5 billion over the next 10 years to accelerate the transition to net zero operations. Giving back is in the DNA of Vedanta, which is focused on enhancing the lives of local communities. The company’s flagship social impact program, Nand Ghars, have been set up as model anganwadis focused on eradicating child malnutrition, providing education, healthcare, and empowering women with skill development. Under the aegis of the Anil Agarwal Foundation, the umbrella entity for Vedanta’s social initiatives, the Vedanta group has pledged Rs 5000 crore over the next five years on social impact programmes with a thrust on nutrition, women & child development, healthcare, animal welfare, and grass-root level sports. Vedanta and the group companies have been featured in Dow Jones Sustainability Index, and was conferred Frost & Sullivan Sustainability Awards 2020, Golden Peacock Award for excellence in Corporate Governance 2022 and certified as a Great Place to Work 2022. Vedanta Limited is listed on the Bombay Stock Exchange and the National Stock Exchange.
For more information, please visit www.vedantalimited.com
About Vedanta Aluminium Business:
Vedanta Aluminium, a business of Vedanta Limited, is India’s largest producer of aluminium, manufacturing more than half of India’s aluminium i.e., 2.37 million tonnes in FY24. It is a leader in value-added aluminium products that find critical applications in core industries. Vedanta Aluminium ranks 1st in the S&P Global Corporate Sustainability Assessment 2023 world rankings for the aluminium industry, a reflection of its leading sustainable development practices. With its world-class aluminium smelters, alumina refinery and power plants in India, the company fulfils its mission of spurring emerging applications of aluminium as the ‘Metal of the Future’ for a greener tomorrow.
For more information, please log on to www.vedantaaluminium.com
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