Manufacturing

Energeia’s Air Compressor Optimization Saves a Paper Manufacturer ₹2.1 Crore Annually

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Executive Summary

Energeia optimized a leading paper manufacturer’s compressed air system by replacing two outdated compressors with an energy-efficient centrifugal compressor featuring turbo, screw technologies, and VFD. This eliminated inefficiencies, saving ₹2.1 Crore annually, reducing energy usage by 35.15 Lakh kWh, and cutting CO₂ emissions by 2,882 tonnes while improving reliability and sustainability.

Key Stats

₹0.1 Crore

Monetary Savings Annually

0,15,000 kWh

Energy Savings Annually

0,882 Tonnes

CO₂ Emission Reduction

Customer Overview

The client, a prominent paper manufacturer in India, relies heavily on compressed air systems essential to its production processes.

Challenges

FAD (Free Air Delivery) Audit

Energeia conducted a detailed FAD (Free Air Delivery) audit using advanced diagnostic tools and IoT-enabled real-time monitoring.

Comprehensive Performance Evaluation:

  • Measured FAD at pressures of 4.8, 5.2, and 5.5 bar.
  • Analyzed specific power consumption for each compressor.

Detailed Analysis:
The audit identified several inefficiencies, including:

  1. Aging Compressors: Models dating from 2005 to 2009 showed declining performance.
  2. Inefficient Compressors: Two compressors exhibited high specific energy consumption (CF1: 0.274 kW/CFM, CF3: 0.465 kW/CFM).
  3. Frequent Wastage: Excessive purging and air wastage during low-load conditions.
  4. Maintenance Issues: Persistent challenges due to outdated equipment.

Energeia’s Solution: Air Compressor Optimization

Energeia replaced two inefficient air compressors with a single energy-efficient centrifugal compressor that delivers industry-leading performance. The new compressor combined turbo and screw technologies with a Variable Frequency Drive (VFD). This optimized setup eliminated air blow-offs and ensured the system operated at maximum efficiency.

Results

  • Energy Savings: Reduced energy consumption by 35,15,000 kWh annually, cutting operating costs by ₹2.1 Crore.
  • CO₂ Emission Reduction: Lowered emissions by 2,883 tonnes annually, aligning with sustainability goals.
  • Enhanced Performance: Improved system reliability and reduced maintenance downtime.

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.