Embracing a Global Vision

At the heart of our mission lies the ambition to deliver extraordinary value to our customers. This guiding principle is not confined to immediate needs; it is a dynamic vision that anticipates the challenges of tomorrow. Our goal to achieve a global top-three position within the next decade is both inspiring and a reminder of the opportunities that lie ahead.

This vision finds expression in initiatives such as the State of the Future Art, a strategic effort to shape—not merely follow—the trajectory of our industry. This initiative exemplifies our belief in the transformative power of forward-thinking ideas and ground-breaking technologies.

Collaboration: The Cornerstone of Innovation

True innovation thrives on collaboration. It requires partnerships that bring together the brightest minds from diverse fields—be it academia, industry, or within our own teams. These connections enrich our approach, ensuring that our solutions are not only cutting-edge but also practical, impactful, and sustainable. Our partnerships allow us to continuously refine and redefine what is possible, driving technological advancements that meet real-world needs. They also remind us that progress is a shared endeavour, achieved through collective effort.

Focusing on Value Creation

In the Product Excellence and Innovation (PE&I) team, we are dedicated to finding new ways to enhance our offerings. Whether through improved performance, cost efficiency, or reliability, our goal is to deliver solutions that resonate with our customers and stand the test of time. This commitment to value creation will be evident during the showcases and presentations held throughout Technology Day. These sessions are more than displays of innovation; they are a testament to the relentless pursuit of excellence by our teams.

The Human Element of Innovation

No discussion about innovation is complete without acknowledging its most critical driver: people. Human dynamics—our creativity, interactions, and passion—fuel the progress we seek. This is why collaboration remains at the core of our culture. As leaders, our role is to inspire and empower teams to think boldly, work collaboratively, and push boundaries.

Honoring Our Legacy, Shaping the Future

Technology Day holds special significance as it coincides with the birthday of our visionary founder, the late Mr. LG Varadarajulu. His pioneering spirit and commitment to innovation laid the foundation for the culture we celebrate today.

This occasion serves as a reminder of our roots and the legacy we aim to build upon. It also inspires us to look forward—to challenge conventions, explore new horizons, and create technologies that will define the next generation.

Moving Forward Together

As we continue on this journey of innovation, I encourage all of us to reflect on the immense potential we hold as a community. Through collaboration, a commitment to excellence, and a shared vision, we will not only meet the challenges of tomorrow but also unlock new opportunities.

Let’s continue to innovate boldly, honoring the legacy of those who came before us and inspiring the generations to come.

At ELGi, we’ve made innovation the core of our business goals to keep up with the changing needs of our customers and the trends in global technology. The driving force behind innovation and sustainability is the efficiency of the product. Over the years, through the meticulous optimization of design, production, and performance, we at ELGi have uncovered a vast array of potential where products not only fulfill present-day requirements but also reduce waste, preserve resources, and ignite a more promising, low-carbon future for our customers.

Today, with an emphasis on improved reliability, efficiency, and performance, ELGi’s innovative technological breakthroughs are pushing the limits of the compressor industry globally. We remain committed to nurturing the entire lifecycle of our offerings – via the relentless pursuit of responsible design, manufacturing, usage, and disposal, ensuring that our products leave a positive imprint on the world, empowering individuals, and businesses to make sustainable compressed air choices.

Innovation is a continuous journey, and a systematic and focused approach will augment the speed and effectiveness of our innovation efforts. This conviction led to the inception of the initiative “State of The Future Art.” This Technology Day, 2023, I am so proud to acknowledge my team’s unwavering dedication, which has resulted in the successful completion of several product development and innovation initiatives. These new developments with enhanced performance, reliability, and features will significantly elevate the overall customer experience with ELGi and contribute to our overarching aspirations.

To conclude, I’d like to refer to something I believe in. Imagine the future and fill in the gaps. That’s innovation! – Dr. Venu Madhav, Director, Technology, ELGi Equipments Limited

With continuous efforts by compressor manufacturers to lead the market on energy efficiency, superior performance, and reliability, it is critically important that the users of air compressors are aware of the advanced product options available in the market. The technological advances in control systems and the evolution of the Internet of Things (IoT) provide further motivation to upgrade the air compressors at the right time. Typically, Air Compressor Upgrades happen in every 3-4 years by manufacturers to improve energy efficiency, reliability, advanced features, etc., and it is worth the while to evaluate the need for upgrading your compressors.

Five critical factors to consider while upgrading your compressor

Energy Efficiency: Energy costs contribute to over 75% of the total life cycle cost (LCC) of a compressor, and is therefore the key factor in upgrading an air compressor. Once the energy cost of the existing compressor is determined (through air audit or a simpler total input power measurement), the benefits of a new compressor, in terms of energy costs, can be evaluated. In cases where the user’s duty cycle of the air compressor has increased significantly over time due to additional production activities, the savings will be more beneficial with shorter return on investment. Additionally, if the plant needs a higher flow for expansion, it is an opportunity to consolidate the need and evaluate for upgradation. The size of the machine (in kW) should also be considered, as the larger the size of the unit, the higher the savings potential.

Advanced features: Significant improvement in controller features, more intelligence through additional sensors, and evolution of IoT capability are further reasons to consider an upgrade. These features result in improved uptime, insights for improvement in energy efficiency, and inputs for optimized operational settings in addition to 24×7 remote monitoring from anywhere in the world. In plants where the failure of a compressed air system can result in heavy losses in productivity, these features are particularly critical. Improvement in consumables’ life and/or reliability is another factor. Recently, ELGi had doubled the life of oil filters used in its oil lubricated rotary screw compressors in several models. All these features not only make the compressors more efficient but also significantly more reliable and advanced.

Breakthrough products: Compressor users must also look out for breakthrough products that will result in superior performance. ELGi has recently launched a product, AB Series with a disruptive oil-free technology that will bring down the life cycle cost of an oil-free compressor significantly. Such breakthrough improvements provide an opportunity to improve overall plant efficiency and performance while meeting the users’ needs effectively. Growing production needs in a plant will also need a different compressor technology such as the transition to centrifugal compressors for larger volumes of compressed air as an example.

Unplanned maintenance costs: As compressors age and when they need frequent attention to keep them running reliably, the unplanned maintenance or repair costs will also increase. If the cost of repairs reaches a certain level (~40-50% of the compressor value), along with the lower energy efficiency of older products, it is an appropriate time to evaluate and upgrade your air compressor.

Return of Investment (RoI): Another important factor to be considered while upgrading the compressor is the RoI. With improv energy costs, the RoI can be evaluated to meet the customer’s target.

Energy costs account for approx. 30% of a production facility’s operating budget. That means nearly a third of all the money organizations invest into their plant, goes straight to the power bill. Power cost is a pivotal determinant of the overall cost to companies. 

Globally, business owners have embraced sustainable techniques to ensure   convenience, and efficiency in their facility, but is it possible to go too green? Absolutely. 

Considering the implications of global warming, ELGi introduced a Heat Recovery System, which enables the reuse of heat energy generated during the compression process for tasks like heating water. 

Refine Your Compressed Air System with ELGi’s Heat Recovery System 

ELGi’s Heat Recovery System can assist in using 78% of the waste heat generated by the compressor for other facility operations, such as heating water. As a result, there is no longer a need to purchase additional equipment to heat water, thus lowering CO2 emissions. The Heat Recovery System is an accessory which can be used with the ELGi EG Series rotary air compressor. Customers can easily plug the HRS into an air compressor to warm water and air for use in showers and boilers by using the heat produced by the air compressor.  

In a typical compression system, the theoretical recoverable heat is 96% of the overall electrical energy consumption. It consists of heat dissipated in the oil cooler (78%), the after cooler (13%) and the heat radiated from the drive motor (5%). The heat dissipated by the oil cooler can be used for heating water and the heat dissipated by the after cooler and drive motor can be used for supplemental space heating. The remaining 4% heat cannot be recovered, since 2% radiates through the canopy and the other 2% vents inside the canopy. 

Robust Operations Across Industries 

The Heat Recovery System finds its operation in industries like automotive, textiles, cement, paper & pulp, machine tool shops, steel making and the food processing industry where there is a need to heat / pre-heat water to a certain temperature ELGi’s HRS can significantly reduce energy costs by eliminating the use of special heating equipment or by offering the initial heat to start the heating process where higher temperatures are required. 

Elgi is a global air compressor manufacturer with an expansive line of innovative and technologically superior compressed air systems. ELGi has consistently ensured that its customers achieve their productivity goals while keeping the environmental impact low. Our product innovation for the Heat Recovery System is driven by the potential for savings and by examining the carbon footprint of an air compressor. ELGi firmly believes that sustainable technology is at the heart of positive environmental change.    

Explore our portfolio of sustainable & efficient solutions here: http://www.elgi.com 

Executive Summary

The agency’s mission is to help people before, during and after disasters across the USA. During the COVID-19 pandemic, the demand for critical healthcare in rural parts of the country rose rapidly while hospitals were overstretched with COVID-19 patients. Quick to act, the agency introduced a medical solution comprising of innovative mobile acute care units ensuring healthcare was more accessible to rural Americans during the pandemic.

Industry Overview

The World Health Organization (WHO) has predicted that Chronic Obstructive Pulmonary Disease (COPD) will be the third leading cause of death worldwide by 2030. With other respiratory diseases like COVID-19 on the rise, oxygen is increasingly being used to treat patients. 

The US has the largest[i]share in the medical gases and equipment industry worldwide. An aging population (By 2034, the US geriatric population is slated to reach 77 million, according to the US Census Bureau), the prevalence of lung diseases like asthma, and a rise in the number of road accidents are some of the other factors leading to more demand for medical gases. 

Organisation Overview

Established in 1979 to assist in disaster efforts, the agency helps coordinate resources during emergencies that overstretch local and state capabilities.. To achieve this goal, the agency works towards empowering everyone with the information they need to prepare for disaster impact. 

They came to the fore during natural disasters like hurricane Katrina in 2005 and are now playing a pivotal role in battling the pandemic..

The agency sought to make medical care available in the country more uniform. Critical healthcare was more readily available in urban America compared to rural locations. With COVID-19 hotspots cropping up in the rural USA in addition to urban areas, it was essential to deliver medical care to rural parts of the country quickly. 

Customer Challenge

About 60 million Americans (around 19%[ii] of the total population) live in rural areas, according to the Centers for Disease Control and Prevention (CDC).

Furthermore, COVID-19 case rates per 100,000 persons were more in rural areas than those in urban. Surprisingly, 63% of rural hospitals do not have ICU beds, making it difficult to treat patients with severe COVID-19 symptoms.. 
During lockdowns, while cities could convert large areas like stadiums into makeshift hospitals, rural areas did not have such infrastructure to do so. Many rural hospitals only had hundred beds and were overwhelmed with COVID-19 cases. Often hard to reach, the agency required mobile units to deliver medical care in such places.

COVID-19 patients were often critical cases, requiring medical-grade breathing air, oxygen, and medical vacuum.. Many components comprise the mobile healthcare unit to ensure purity and dryness complies with NFPA 99 regulations. Thus, building and assembling the smallest unit possible to ensure mobility and code compliance was a challenge.

The Solution

Pattons Medical had developed mobile medical units before the pandemic, but these units became even more critical during COVID-19. Their experience in developing and putting together the smallest possible units helped make optimal mobile ICU units.
Each component of the unit was tested intensively to ensure high quality of operation, easy to install and maintain.

The mobile unit built is a semi-track that, when in place, has panels that expand to fit patients. Hoses with specific fittings coil up to fit in the mobile unit. When these pipes are uncoiled at the site, valve outlets ensure the mobile units work like hospitals on the go.

To combat the c challenge in a mobile unit, Pattons Medical used open configurations to protect pumps. Medical air compressors were used to dry ventilators; as the air is moist and gets into the patients’ lungs, that moisture could be enough to drown them.

In mobile systems, manifolds supply oxygen through eight-cylinder tanks. They employ pressure to force the oxygen through valves and into pipes where nurses may administer it to patients. In the event of a loss of air pressure, alarms are installed on both sides of the semi-track to turn off oxygen and air.

Business Benefits

Wes Chancellor, a Medical Gas Foreman, said, “We were very impressed with the high quality of all equipment shipped to us.” 

Josh Pedraja, Medical Gas/Lab Consultant at Pattons Medical, said, “When I set foot in the first trailer as it was being built, I had a great sense of joy and pride knowing that I helped design these trailers to assist others in times of need. Post pandemic, these trailers will be used for relief work during natural disasters such as hurricanes and tornadoes.”

Conclusion

The agency assisted rural hospitals in the United States in providing crucial healthcare to patients. Their dedication to provide rapid emergency care enabled them to deliver mobile ICU units wherever they were needed the most.

As the pandemic persists, there is a consistent demand for these units. Pattons Medical, as a socially responsible organisation, manufactures these mobile medical units that the agency certifies are equal to those in hospitals.

Information resources:

[i] https://www.mordorintelligence.com/industry-reports/global-medical-gases-38-equipment-market-industry

[ii] https://www.idsociety.org/globalassets/idsa/public-health/covid-19/covid19-health-disparities-in-rural-communities_leadership-review_final_ab_clean.pdf 

This approach has primarily contributed to “what we are’’ and ‘’where we are’’ today. A broad spectrum of our customer’s manufacturing facilities has been evolving rapidly while adopting new technology that improves their existing processes. Today, we’re proud to see our high-value, customer-centric products in great demand in over 120 countries across the globe!

Innovation is a continuous journey – a race that has no finish line, and so is the case with our business aspirations. ELGi stands tall as one of the global leaders in the compressed air industry. Over the years, customer value and quality have been intrinsic to our DNA and we believe innovation will help us  in achieving our growth goals.   

With an in-depth understanding of the “know-how” and the “know-why” of compressors, it gives us the ability to build globally competitive products.

In the current dynamic technological arena, the speed and effectiveness of innovation are critical to be ahead in the game. A systematic and focussed approach will enhance the speed and effectiveness of innovation. Which brings us to the initiative –  State of The Future Art, where we aim to identify, develop, and nurture innovation systematically.

Celebrated every year on the 15^th of December, the ‘State of The Future Art’ themed Technology Day brings together young engineering minds from the ELGi Global Technology Center, the academia and industry experts, and provides a robust platform for them to ideate and showcase breakthrough technology through a series of presentations, product displays, knowledge sharing and interactive panel discussions. This year’s focus is on Energy Efficiency.

Our work extends to expanding the range and incorporating region-specific features to handle challenging environmental factors and associated needs. We believe this will attract many more global customers and enhance our strengths while we march towards our aspirations.

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Therefore, businesses equip their manufacturing processes with screw air compressors.

So, what are screw air compressors?

Screw air compressors or rotary screw air compressors are an advanced version of the original piston air compressors. Using a rotary type positive displacement mechanism, they are the workhorses that provide large volumes of medium to high-pressure air in large factories. The screw air compressors find their use in food production, beverages and medicines, construction, mining, petrochemical engineering and more.

Types of rotary screw air compressors:

Industries and manufacturing plants widely use two types of rotary screw air compressors: oil-free and oil-lubricated rotary screw air compressors. Each of these is unique in their way and are suited for specific purposes.

Oil-free screw air compressors:

In an oil-free screw air compressor, the air is compressed entirely through the action of the screws without the assistance of oil lubrication. Instead, PTFE, distilled water or other proprietary coatings are used for lubrication and heat dissipation. They usually have lower to medium discharge pressure capability as a result. However, higher pressure can be achieved by multi-stage oil-free compressors, where the air is compressed in multiple stages.

Oil-free screw air compressors are used in applications where even the slightest bit of oil contamination cannot be tolerated, including the production of food and beverages, medicines and medical research, packaging, and more.

Oil-lubricated screw air compressors:

Oil is injected into the compression chamber to aid lubrication and adequate heat dissipation in an oil-lubricated rotary screw compressor. The oil is separated from the discharge stream, cooled, filtered, and recycled.

Oil-lubricated screw air compressors are used in applications that require or can tolerate slight levels of oil, such as tools, heavy drilling and mining, metallurgy, mobile tire services, and more.

Benefits of screw air compressors

A. Continuous flow: There is no disruption in the delivery of air for any application.

B. Flexible and durable: They can be designed for extreme weather conditions as well.

C. Lower maintenance costs: The innovative design is ideal for customer needs, ensuring that the equipment functions smoothly and hence no unwanted costs.

D. Low noise output: These compressors run quietly and provide a safe working environment.

Rotary screw air compressors by ELGi:

The rotary screw air compressors are the backbone of most industries across the globe. The proprietary airend design, advanced features, and innovative technology offer cost-effective, long-lasting, reliable, and premium compressed air perfectly suitable for light to heavy-duty industrial applications.

AB series

ELGi’s new AB series screw air compressors provide disruptive benefits in terms of efficiency, reliability, and air quality, resulting in lower life cycle costs and high uptime.

The high-quality air output with Class ‘0’ certification makes ELGi’s screw air compressor ideal for sensitive applications like producing and manufacturing food and beverages, pharmaceuticals and medicines and medical research.

EG series

A trusted solution for partners from across the globe, the EG series air compressors from ELGi are highly efficient, reliable and have a long life. These features of the air compressors support the packaging industry in maintaining quality, safety, and reliability.

You can reach out to our air experts for support with your business: https://www.elgi.com/in/rotary-screw-air-compressors/

In such a scenario, it is of utmost importance to nurture a culture, wherein women have equal opportunity to participate in the workforce while gaining access to unlock their true potential. To foster such an environment, the need for offering young girls inclusive and quality education, aided by affordable vocational training, is more critical than ever before.

Currently, over 132 million girls are out of school. If we put it more elementally, on an average, 1 in 4 girls do not go to school.

With such staggering numbers, the need for providing young women access to sound education is imperative. This is why, at ELGi, strive to champion this cause with the ELGi Matriculation Higher Secondary School, an ELGi Public Welfare Trust initiative.

In line with the United Nations’ 4th Sustainable Development Goal to provide ‘Quality Education’, our young female students are encouraged to pursue their studies in STEM subjects and take part in the National Children Science Congress. This has been met with much enthusiasm and our female students have gone on to win awards at both the district and state levels.

This Women’s Day, let us take a look at the perspectives of the educators at the ELGi school, who have taken on the responsibility to mould our female students to be leaders who #InspireTheFuture.

At ELGi, we monitor data and feedback, to produce small changes which accrue over time to positively impact culture and business vision. Taking feedback and implementing improvements helps set up an effective loop where culture and processes benefit from each other so the business can make bold decisions for the future.

With the introduction of quality management systems, the focus has now shifted to removing inefficiencies from the system, breaking down barriers in management and making collective improvements.

At ELGi, we monitor data and feedback, to produce small changes which accrue over time to positively impact culture and business vision. Taking feedback and implementing improvements helps set up an effective loop where culture and processes benefit from each other so the business can make bold decisions for the future.

With the introduction of quality management systems, the focus has now shifted to removing inefficiencies from the system, breaking down barriers in management and making collective improvements.