Smart Compressed Air Management: A Journey from Generation to Machine-Level Efficiency

At Systel Energy Solutions, we're continually innovating and expanding our smart compressed air management capabilities. Recently, we've extended our Smart Compressed Air Management System beyond compressed air generation and production header monitoring to include individual machine-level consumption tracking. This enhancement was made possible through our Compact Thermal Mass Flow Sensors, Model WAFS - 108. Here's an insightful overview of the project and its significant outcomes:

Prologue

Our customer is a modern Ring Spinning Mill with an impressive capacity of 75,000 spindles, primarily producing 60s counts. Initially, the factory's compressed air consumption was substantial, totaling 550 CFM and consuming about 83 kW per hour, translating roughly to 2,000 kWh per day.

First Implementation

To address energy efficiency comprehensively, WiseAir digitalized the factory's compressed air system, installing our advanced Energy, Flow, Dew Point, and Pressure Sensors at both generation and consumption headers. This setup allowed for real-time monitoring via our cutting-edge WASM 604 Smart Monitoring Software.

Initial Results

Real-time data gathered revealed considerable opportunities for optimization throughout the facility. With informed interventions, compressed air consumption was nearly halved, dropping to 230 CFM, and power consumption reduced by approximately 950 kWh daily. This impressive reduction directly translates into substantial cost savings:

• Daily savings: 950 kWh/day × ₹8.2/kWh = ₹7,790/day

• Monthly savings: ₹7,790/day × 30 days ≈ ₹233,700/month

• Annual savings: ₹233,700/month × 12 ≈ ₹2,804,400/year

Second Initiative

Having stabilized their optimized consumption for several years, the factory sought additional improvements. Analysis of header consumption data suggested further savings were achievable, particularly from Autoconer machines. However, manually measuring these machines' daily consumption proved impractical. To overcome this, WiseAir installed the compact WAFS-108 flow sensors on each Autoconer machine, enabling precise, real-time tracking in our WASM 604 software. This continuous monitoring quickly uncovered previously undetected system leaks and inefficiencies under varying operational conditions.

Result

Thanks to machine-level monitoring, the factory achieved additional reductions in air consumption, from 230 CFM to 195 CFM, and further decreased daily power use from 950 kWh to 805 kWh. These reductions are projected to yield an additional annual savings of approximately ₹430,000. Remarkably, the project's overall payback period has been under 8 months, highlighting both the effectiveness and economic viability of WiseAir's Smart Monitoring Solutions.

At WiseAir Technologies, we're committed to empowering industries with data-driven insights and innovative technologies, helping them achieve significant efficiency gains and sustainable cost savings.