Automotive

Global Automotive Manufacturing Facility Saves 2.75 Lakh kWh in Compressed Air System

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Executive Summary

A global automotive component manufacturer struggled with inefficient compressed air systems in their Jaipur facility. Energeia’s comprehensive compressed air audit revealed substantial energy-saving opportunities. Our recommendations, including compressor replacements, centralized control systems and operational optimizations, delivered annual savings of 2,75,391 kWh, translating to ₹22 lakh in cost savings.

Key Stats

₹0 Lakh

Monetary Savings Annually

0,75,391 kWh

Energy Savings Annually

0.8 Tonnes

CO₂ Emission Reduction

Customer Overview

The client is a leading provider of technology and services in India, with a strong presence in Mobility Solutions, Industrial Technology, Consumer Goods, and Energy & Building Technology. The Jaipur factory is one of the company’s many manufacturing sites in India. This plant plays a crucial role in its automotive component manufacturing operations.

The Challenges

  • Energy Inefficiency: The compressed air system was operating at a higher specific power consumption (0.255 kW/CFM) compared to the industry standard (0.180 kW/CFM).
  • Mismatched Capacity: The existing compressor setup was not optimized for varying demand, especially during night shifts.
  • Operational Inefficiencies: Multiple compressors were often running simultaneously, leading to energy wastage.
  • Lack of Centralized Control: Absence of a centralized system resulted in suboptimal compressor sequencing and operation.
  • High Energy Costs: The plant was spending approximately ₹63 lakh annually on energy for the compressed air system.

Energeia’s Solution: E-Air Optimization

Energeia conducted a detailed audit of the compressed air system and proposed a comprehensive optimization strategy:

  • Compressor Replacement:
    • Smaller VFD-driven compressor for night shifts
    • An Energy-efficient compressor for day shifts with higher FAD, eliminating the need to run two air compressors
  • Centralized Control System  implementation for optimized compressor sequencing during different demand requirements
  • Additional Recommendations:
    • Buffer air receiver installation
    • Level-based auto drain system
    • Energy-efficient air guns
    • Aluminum piping consideration

Results

  1. Energy Savings: Annual reduction in energy consumption by 2,75,391 kWh
  2. CO₂ Emission Reduction: 236.8 Tonnes annually
  3. Operational Improvements:
    • Improved specific power consumption from 0.255 kW/CFM to as low as 0.18 kW/CFM
    • Enhanced system reliability and reduced equipment wear
  4. Cost Savings:
    • Significant reduction in energy costs of approximately ₹22 Lakh per year
    • Decreased maintenance expenses due to optimized equipment operation
  5. Sustainability:
    • Alignment with the company’s commitment to technological excellence and environmental responsibility
    • Contribution to global sustainability initiatives in automotive manufacturing

Let's Connect

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Sankriti Malik

Head, Marketing & Growth

Sankriti is a dynamic growth catalyst, turning customer insights into impactful strategies.

She’s held multifaceted roles at high-growth startups like Kodo Tech, Athena Education, and Hora.AI, where she drove initiatives in product management, UX research, and branding. She’s also contributed to strategy roles at Indian Oil, Times Internet (BCCL) and The Copenhagen Post.

A Psi Chi Honors graduate from Wesleyan University in the US, Sankriti blends her expertise in UX design, data, and strategy to lead Energeia’s marketing efforts – always keeping the customer at the heart of her work. 
 
She’s passionate about gender equity in climate tech and actively contributes to networks like Leap.club and Ladies Who Lead. Her commitment to impactful digital design led her to join communities like GrowthX, IxDF, and Terra.do. In the past, she’s been a Fellow at the Patricelli Center for Social Entrepreneurship and co-founder of the Design Think Tank.