Improve product quality and reduce losses in production through Godrej
This case study reveals how Godrej’s Compressed Air Solutions improved the compressed air system efficiency in one of largest textile plant with energy savings and reducing production losses.
Godrej Compressed Air Solutions improved the efficiency of compressed air systems in one of largest textile manufacturing company based in Southern India leading to energy savings of 1,600 kWh/day and reduction in yarn breakages.
Foreword
Compressed air which is industry’s 4th utility is the most expensive utility, consuming approximately 20 per cent to 22 per cent of the total energy consumption of the entire factory in textile industry sector.
This case study offers insights on how our compressed air solutions have helped one of the textile plants achieve energy savings in their compressed air network.
Overview
One of the largest textile manufacturers based out of Southern India.
This manufacturing facility in Southern India has an installed capacity of 125 tonne of medical material per month. Weaving shop is highly dependent on compressed air for its processes which is fulfilled by a centralised compressed air network.
A major problem faced by the textile manufacturer was very high energy consumption of air compressors i.e., 14,500 kWh/day and pressure fluctuations leading to yarn breakage & inconsistent product quality.
So, the client decided to utilise the expertise of Godrej Compressed Air Solution to understand the possible energy saving potential in their compressed air system and nullify the pressure fluctuation.
Step 1: Feasibility study visit
Godrej CAS team conducted a feasibility study using data logging instruments in the existing compressed air network to understand the operation patterns of compressors, variations in plant air demand and to work out a suitable solution along-with an estimation of envisaged energy savings.
The Textile manufacturer has been using the following air compressors to fulfill their compressed air requirements in their plant.
Godrej CAS team installed instruments to simultaneously carry out real time data logging as a part of the feasibility study in the complete compressed air system
Data logging instruments were installed at multiple locations viz:
- Generation – Compressor house B & C
- Application – Weaving looms
Pressure drop was checked in compressor house as well as in application points.
The gathered data was then analysed to estimate the artificial demand currently present in the system which was causing pressure fluctuation and resulting in higher energy consumption.
Step 2: Observations & findings
- During the feasibility study, pressure fluctuation in application was found to be
96 psig (6.6 barg) to 84 psig (5.8 barg) which resulted in up-to 20 per cent artificial demand leading to increased energy consumption of air compressors.
- Compressor’s energy consumption was around 14,500 kWh/day
The status before:Pressure variation in compressed air system from 96 psig to 84 psig
Step 3: Problems identified & solutions offered
After analysing the measured data, Godrej CAS team worked out a suitable solution and submitted an energy saving proposal.
It was recommended to install ControlAiR IFC – demand side management systems for weaving plant to reduce the artificial demand by optimising flow & pressure supplied to shop leading to huge energy savings and constant compressed air pressure in each shop could be achieved.
With installation of Demand Side Management Control Systems, it was envisaged to provide
- Constant pressure to the plant = within +/- 0.5 psig (0.03 barg).
- Energy saving in Compressed Air System =580 kWh/day @ 4%
Step 4: Implementation & results
As per the recommendations, the manufacturer installed ControlAiR IFC systems for Compressor Room C,
By implementing the recommendations of the Godrej Compressed Air Systems, the textile manufacturer was able to realise dead constant air pressure in plant, reduced artificial demand up-to 18% and ultimately energy saving in Air Compressors.
Benefits
- Constant air pressure with ControlAiR IFCs = ± 0.5 psig (± 0.03 barg)
- Actual energy saving achieved = 11 % @ 1600 kWh/day
- Reduction in CO2 emissions = 450 T/year
- Simple payback period = Less than 1 year
With installation of Godrej ControlAiR IFC Systems the pressure in application was observed to be constant within +/- 0.5 psig. (+/- 0.03 barg.) Constant pressure in the plant helps in:-
- Reduction in production losses due to yarn breakage, and thus improving the product quality.
- Reduction in Compressed Air Leakages by 15 per cent.
- Consistency in pneumatic equipment performance due to constant pressure.
Real time pressure trends with Godrej ControlAiR™ IFC in textile plant
With Godrej ControlAiR IFCs installed in textile plant exact demand in terms of flow & pressure is matched and very stable pressure within +/- 0.5 psig is provided to application.
Set Pressure: 77 psig
| Generation pressure fluctuating from 85 psig to 77 psig (5.8 barg to 5.3 barg) |
Air compressors performance with & without IFC
The Textile manufacturer had ten screw load/unload and one screw VSD compressors to fulfill the compressed air demand.
Godrej CAS team with its extensive experience, recommended a solution which directly impacted on working pattern of compressors leading to reduced artificial demand and good energy saving.
“The overall Compressed air system efficiency can be optimised effectively when both demand and generation operate in sync with each other. This can result in 15 to 20% energy saving.”
Rohit Shetty
Associate General Manager & Business Head GCEM Dept, Godrej Electricals & Electronics
About the author:
Prasad Shrirame, Product Manager – Godrej Compressed Air Solution, Godrej & Boyce Mfg, Co. Ltd.
Contact us on casene@godrej.com;
shrirame@godrej.com
