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Results

Measured on the customer's own sensors. Read against the Systel Audit Archive.

Figures are from plants on the programme, read from their dashboards against a measured baseline. Customer names and logos appear only with written approval; more case studies are added as customers approve them.

Case study · Textiles · spinning · on the programme since 2019

The compressors said 0.16 kW/CFM. The sensors said 0.196.

A 100,000-spindle mill in Tamil Nadu ran two screw compressors, 850 and 450 CFM, 132 and 75 kW, at a paper specific energy of 0.16 kW/CFM. The plant wanted to get from about 1,300 CFM to 600 and did not know where to begin.

The monitoring system showed the pair delivering 1,120 CFM for about 220 kW: 0.196 kW/CFM, 18% worse than claimed. Spinning and autoconer were drawing 800 CFM against a need of about 300; preparatory 320 against 50. The archive had seen both patterns before: artificial demand from over-set machine pressures, and leaks that returned after every survey.

0.196 → 0.17kW/CFM after supply-side settings and maintenance · 537 kWh/day
1,300 → 560CFM, two years after the project — below the 620 CFM reached at hand-over
< 6 monthspayback on the digitization project and monitoring system
What the plant's team did, from the daily readings
  • Reset machine operating pressures in spinning, autoconer and preparatory — about 150 CFM of artificial demand removed
  • Fixed leaks department by department, watching each department's daily consumption instead of waiting for the next survey — about 350 CFM
  • Adjusted compressor inlet, ambient and set-point conditions and carried out the maintenance the readings pointed to
  • Avoided the large spares earlier leak-survey agencies had recommended — spares spend down by about 60%
Annual savings reported by the mill: ₹12.56 lakh on the supply side and ₹47.73 lakh on the demand side at ₹6.5/kWh. Already published on systel.asia; figures as reported by the plant.

What would your plant measure?

A feasibility visit gives a tentative projection. The baseline gives the real number.

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