Alantech Conducted an Energy Audit and Saved 80,000 kWh Annually for a Major Tyre Manufacturer
About the Customer
The customer is a leading tyre manufacturer in India, with a strong presence in both domestic and international markets. The company is a leading provider of quality, innovative, and operationally excellent solutions. It operates large, complex manufacturing facilities that depend on highly efficient utility systems in order to support the continuous manufacturing process.
The Situation
The customer’s cooling water circulation system was running oversized, high-kW pumps that had been installed years before. The pumps were throttled and operated continuously to provide the required process flow.
Apart from that, years of scale buildup within the aging pipeline network had increased flow resistance, leading to a decline in overall system efficiency. As a result, the facility faced several issues:
- Power consumption is too high
- Managing the balance and flow within the system is difficult
- Lowered pumping efficiency
- Increased operating cost
- Concerns about maintenance
The customer wanted a practical solution to optimize system performance and minimize energy consumption.
The Challenge
The main challenge was to determine the actual flow requirement of the cooling water system and to determine if the existing pumps were sized correctly for the application.
The plant operating conditions had changed over time but the pumping system had never been re-evaluated. The expansion of pipelines compounded the problems of flow management, and the use of large pumps at throttled conditions led to large energy waste.
A detailed technical assessment was necessary to find the most energy-efficient solution while maintaining process reliability.
The Solution
Alantech performed a detailed energy audit on the cooling water circulation system.
The audit consisted of:
- Measurement of the actual flow requirements of the system
- Analysis of the power consumption pattern
- Pump operating point calculation
- Evaluation of pipeline conditions and flow constraints
- Study of the optimization of system performance
The findings resulted in Alantech recommending that the oversized existing pumps be replaced with appropriately sized, high-efficiency Grundfos cooling water circulation pumps that matched the actual system demand.
The new pump selection resulted in the system operating closer to the Best Efficiency Point (BEP), resulting in better flow control and less wasted energy.
The Outcome
The optimized pumping solution resulted in significant energy and cost savings, while enhancing overall system performance.
Results Achieved
| Parameter | Before Optimization | After Optimization |
| Annual Energy Consumption | 200,424 kWh | 119,700 kWh |
| Annual Energy Savings | - | 80,724 kWh |
| Annual Cost Savings | - | ₹5.65 Lakhs |
Key Benefits
- 80,724 kWh of energy saved each year
- Annual cost saving of Rs. 5.65 lakhs
- Enhanced flow control and system stability
- Fully automated system
- Improved pump efficiency in operation
- Reduced overall operating costs
- Lower power consumption leads to better sustainability
Conclusion
The project shows that careful selection of pumps and optimization of the system can result in substantial energy savings in industrial applications. Alantech performed a comprehensive energy audit and replaced the undersized pumps with correctly engineered Grundfos cooling water circulation pumps, enabling the customer to reduce power consumption and improve operational efficiency significantly.
Partner with Alantech for Energy-Efficient Pumping Solutions
High energy bills? Inefficient pump operation? Process flow challenges? Alantech can help. Our expertise is in energy audits, pump system optimization, and high-efficiency Grundfos pumping solutions that deliver real results that last. Contact Alantech today to discover how your plant can reduce energy consumption and improve operational performance.
