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How do you handle high-power consuming heaters

Virgo Polymers Saves Rs. 1,22,400 on Energy Bills by Replacing Heaters

Virgo Polymers

Customer Profile:

Virgo Polymers (India) Ltd, a manufacturing plant working in Polypropylene Woven Sack industry for over two decades, cater to the bulk packaging needs of various Industries pan India as well as, transships to 10 countries in 4 continents across the globe.

Case Study:

Virgo wanted to explore energy efficiency possibilities in order to save energy cost. Usually factories consider the following energy saving options:

  • Rooftop solar options or buying solar power from third party farms.
  • Changing motors to servo motors
  • Looking at all electric machinery
  • Extensive energy audits

But Virgo wanted to try out energy analytics, the normal practice is using energy meters for each of the machines used within a factory and there by comparing machine-to-machine electrical data. However, they tried something different.

Virgo used Energyly’s energy monitoring device and web application to study the intramachine components energy consumption pattern. They did so by fixing the CT censors as mentioned below

  • 3 sensors for incoming supply,
  • 3 sensors for motor and
  • 3 sensors for heaters.

Through this diagnosis, they found that heaters within the extruder consumes (70kw/h). On identifying such high power usage by heaters, Virgo began to find alternative technologies to reduce heat power consumption.

As an alternative source they used Nano based Infra Red (IR) to replace the existing band heater which thereby resulted in saving 35 kw/h leading up to reducing their energy costs by 14400 units per month and saving Rs. 1,22,400 on energy bills monthly.

Background

Leading business turn to Energyly to reduce their energy bills up to 25%

Energyly has now over 1500+ customers spanning across multiple industries such as Manufacturing, Retail, Hospitality etc., and 30% of them are from Plastics Industry who have a turnover from 1 crore upto over 200 Crores.

Most of them use it only as a real-time energy monitoring tool to find out if the machines are working, and track downtime, machine to machine performance.

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