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An operator was performing plug-and-perf completions on a seven-well pad in South Texas and was looking for a plug option that would improve operational efficiency through ease of installation and increased run-in and drillout speeds.

They chose to run the MILLITE™ lightweight frac plug from Baker Hughes, a GE company (BHGE). The MILLITE plug is built completely out of a robust, engineered alloy material that is 70% lighter than conventional composite plugs. It generates fewer, smaller cuttings with less total volume of debris per plug. MILLITE plugs also ship direct to location with a pre-installed mandrel, ready to be placed directly on the setting tool, further speeding up job time.

Unlike traditional composite plugs, the MILLITE frac plug was designed using proven friction slips−versus heavy cast iron slips or ceramic buttons−to keep it firmly in the casing. The plug offers a wear and impact resistant bottom sub that transfers impact resistance up through the tool, instead of to the slips or elastomer, making it virtually impossible to preset, even through tricky dogleg angles and extended laterals.

Download the PDF to read the full case study.

Challenges & Results


  • Customer wanted to accelerate plug milling and improve debris removal


  • Milled 190 plugs over a seven well pad in an average of four to under ten minutes each
  • Experienced zero motor stalls or short trips
  • Saved $93,000 USD in chemical cleanout savings
  • Saved 56 hours in drillout time
  • Improved hole cleaning
  • Minimized intervention time and CT cycling costs