Electricity & Diesel Savings at Textile Manufacturer

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Customer has installed different types of looms to cater to diverse segments of the carpet market.

Textile Industry

Electricity & Diesel Savings at Textile Manufacturer

The deployment of ECOTIO platform at a textile industry resulted in identification and arresting of non-peak/wasteful consumption and off day consumption. Also, the client was able to significantly reduce the diesel consumed in their Diesel Genset (DG), which was used for backup power.

The carpet manufacturer based out of Panipat, intended to track their production with respect to the amount of electricity consumption. They had low PF owing to some of their looms which they want to address. Further, they had high running diesel bills owing to the use of DGs during power failures.

The ECOTIO team spent time understanding the client requirement and identifying the key nodal points to deploy the solution. After receiving go ahead from the client, the solution was deployed at 14 nodal points within the premises and thereafter the resulting data was analysed. The following were the key findings and subsequent actions:

Looms running on Low PF were identified and reported to the client. Savings of 14% was achieved after electric drives were introduced on those Looms  

During mapping of the production vs consumption data, idle running hours were identified for some of the machines

Client’s non-peak/wasteful consumption and off day consumption were accurately tracked. Those  nodes along with time of the day(at which wasteful consumption was happening) were spotted and communicated to the Plant Incharge

Client had an old DG and later they got Solar plant installed. Though both Solar & DG were synced, however, during the case of power failure, the diesel consumption remained high. After the solar & DG data was analysed on the ECOTIO platform, it was understood that owing to the higher rating of the DG, the solar plant was not utilized to it’s utmost potential. Intermittent load, solar & DG data were analysed to compute the correct rating of the DG set. After the DG was replaced, 40% reduction was observed in the diesel costs.

With the implementation of the ECOTIO solution, the client was able to reduce 24% in their energy costs, in addition to gaining more control over their factory operations.

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