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Case Study:

A Western India based vertically integrated automobile parts manufacturer for mass production of electrical fittings and metal castings and injection molded products as well as accessories

Automobile

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Problem

- Continuous loss of compressed air due to artificial demand in the process

- Increase in power consumption and energy bills

Objective

To identify the areas that consume excess pressure and eliminate the problem of artificial demand.

Solution

Integration of Forbes Marshall's Master Air Controller (MAC) at the main header of the generation section (compressor house).

Advantages

- Constant and regulated supply of compressed air

- Reduced load-unload cycles leading to decrease in power consumption as the compressor now only caters to the base demand

- Sudden surges in demand taken care of using the buffer storage available in the MAC receiver tank

Benefits

- 8% per annum savings on compressed air costs

- Energy savings through a significant reduction in artificial demand across the plant