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CASE STUDY > BALCO

How BALCO set a new benchmark in aluminium smelting safety using VR, with a 99.6% pass rate

How BALCO’s VR training deployment is setting the benchmark for safety culture in aluminium smelting

3 VR training modules

deployed for high-consequence safety scenarios

99.6% pass rate

across 9 months of deployment

3 VR training modules

deployed for high-consequence safety scenarios

99.6% pass rate

across 9 months of deployment

BALCO, one of India's most critical aluminium producers, deployed immersive VR training with AutoVRse for its highest-risk emergency scenarios — achieving a 99.6% assessment pass rate.

BALCO is one of India's leading aluminium producers and operates one of the country's largest aluminium smelters. It manufactures the metal that powers industries ranging from automotive and aerospace to power, construction and infrastructure.

Training employees for outcomes that are too dangerous to recreate on the plant floor

Years of rigorous safety practices have made catastrophic potline emergencies extremely rare. But that created a new challenge: How do you prepare workers for emergencies they may never experience?

Critical events like pot blasts, pot leakages and open circuit failures are too dangerous to recreate on the plant floor.

Many haven't occurred at BALCO in over two decades, leaving newer workers without real-world exposure.

BALCO needed a way to train every employee and contractor to respond with confidence—without introducing any risk.

Years of rigorous safety practices have made catastrophic potline emergencies extremely rare. But that created a new challenge: How do you prepare workers for emergencies they may never experience?

Critical events like pot blasts, pot leakages and open circuit failures are too dangerous to recreate on the plant floor.

Many haven't occurred at BALCO in over two decades, leaving newer workers without real-world exposure.

BALCO needed a way to train every employee and contractor to respond with confidence—without introducing any risk.

Recreating emergencies in virtual reality

BALCO partnered with AutoVRse to recreate its Korba smelter in virtual reality and transform its emergency SOPs into immersive, hands-on training.

Three VR modules were developed for:

Pot Leakage
Pot Blast
Open Circuit

Instead of reading procedures, workers perform every step inside a realistic digital twin of their own workplace, building confidence before a real emergency ever occurs.

BALCO partnered with AutoVRse to recreate its Korba smelter in virtual reality and transform its emergency SOPs into immersive, hands-on training.

Three VR modules were developed for:

Pot Leakage
Pot Blast
Open Circuit

Instead of reading procedures, workers perform every step inside a realistic digital twin of their own workplace, building confidence before a real emergency ever occurs.

Designed for real industrial operations

The deployment was built around BALCO's operational realities.

Train the impossible
Workers safely practise emergencies that cannot be simulated in real life.

Fits within shifts
Each module averages 13 minutes, making training easy to schedule without affecting production.

Competency, not compliance
Built-in assessments measure knowledge retention and workforce readiness—not just completion.

Accessible to everyone
Simple interactions allow both permanent employees and contractors to complete training with minimal onboarding.

Achieving an 99.6% assessment pass rate

After nine months of deployment, the programme has become another pillar of BALCO's safety culture.

99.6% assessment pass rate
92.5% average assessment score
89% workforce completion
No measurable performance gap between employees and contractors
13-minute average module duration

The result isn't just high participation—it's a workforce consistently demonstrating the ability to respond to high-consequence emergencies.

A new benchmark is set

The success of the deployment has sparked broader adoption across the Vedanta ecosystem, with discussions underway for a 50-module VR rollout across multiple businesses.

It has also led to new deployments, including NGSL, where AutoVRse is developing VR training for Fire Safety, Electrical Safety, Confined Spaces, Working at Height and Driver Safety.

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