Case Study - Rubber Industry


Challenges

  • The rubber plant @ Chennai designed to GA 30 (fixed speed) base load (2 nos) & GA 55VSD (peak demand)
  • Down the years due to losses in overall system they were forced to run GA 55VSD @ 90% which increased their energy consumption with an overall impact on manufacturing cost of end product.

  • The Rubber Industry was started in 1996 and established a global imprint with operations in North America, Europe, Middle East, South East Asia within two decades
  • Today engages more than 1800 employees in its worldwide operation with an aspiration to make the most preferred brand in the international market

Solution

  • Conducted Air Audit from Generation to End Application by our Professionals
  • Procured materials for the identified rectification
  • Carried out Compressor Efficiency Measurement, Leak Analysis, Identification of Leaks Application Wise, etc
  • Within a month, our expert team completed implementation with 900 kwh/day savings


Benefits

  • Achieved committed savings of 900 kwh/day
  • Compressor GA 55 was brought down to 25% from 90% load
  • Overall consumption reduced up to 30%
  • Completed project within a month including audit
  • ROI within 6 months

As the Client was highly satisfied with the Energy savings achieved, project has been implemented in 2 other factories of their concern







Case Study - Tyre Industry


Challenges

  • We partnered with leading tyre manufacturers – Mission Million Project for Compressed Air Energy Management System.
  • The scope of work includes Air Leakage Rectification, Peak Demand Optimization, Misuses, Pressure Drop Analysis, Pneumatic Conversion, etc.

  • An Indian multinational company and the largest manufacturer of tyres in India and fourteenth largest manufacturer in the world.
  • The company manufactures rubber products including tyres, treads, tubes and conveyor belts, paints and toys.

Solution

  • Started Audit phase in 3 different departments simultaneously by engaging with 3 teams and identified 40% loss with detailed report
  • Implemented all the necessary rectifications with our technicians to achieve the committed savings


Benefits

  • Brought down consumption from 11420 to 10399 cfm
  • Achieved 1021 cfm of savings
  • Loss reduction upto 42% was achieved in phase II
  • Brought down SPC from 117 to 90kwh per ton of production
  • Operating line pressure was reduced up to 1.30 bar

Procured huge no of advanced flow meters for their real time monitoring system to analysis the compressor parameters.







Case Study - Textile Industry


Challenges

  • To optimize the compressed air demand
  • To trap 620cfm air loss
  • Initially plant was running with 1500 cfm, but after few years with same production capacity its consumption gradually increased upto 2200 cfm
  • Faced pressure drop fluctuation which resulted in quality issue

  • A worldwide renowned manufacturers and exporters of knitting and weaving yarn with vast experience of 30 years in this field and spindle capacity of 65000.
  • They have clients globally in Bangladesh, Brazil, Bulgaria, Chile, Egypt, Germany, Greece, Iran, Israel, Italy, Lithuania, Mexico, Morocco, Poland, Portugal, and South Africa.

Solution

  • With audit report we observed huge savings of 600 cfm
  • Implemented rectification phase with latest conversion spares which resulted in huge reflection of savings
  • Redesigned piping layout for better flow and changed each Compressor settings for efficient utilisation
  • Real time monitoring solution was fixed to analyse compressor parameter on daily basis.


Benefits

  • Factory is running on optimum load
  • One compressor & its dryer made standby. So no energy consumption & AMC
  • Line pressure drop eliminated, quality & production improved
  • Auto report generation about compressor helps to maintain the above result
  • ROI was within 10 months

Client was happy with the service implemented Real Time Monitoring System to monitor & alert Compressor Parameter






Contact With Us

Contact info

  • Address  :  Velstan Compressed Air Solutions,
    109, Pillaiyar Kovil Street, Kattor, Coimbatore,-641 009
    TamilNadu, India
  • E-mail     :   info@velstangroups.com , velstangroup@gmail.com
  • Phone     :  0422-4355520
  • Mobile    :  +91-98438 75520 / 35520

Working Hours

  • Mon-Sat  :  9.30 am to 6.30 pm
  • Sunday    :  Closed