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 

Take a look at the key points to focus on a compressor’s installation. 

1. LOWER THE PRESSURE
   We all know that working under pressure can be hard! Every additional bar of pressure can increase your power consumption by 7%. Set your air compressor at the lowest possible pressure for a specific application. Remember that increasing pressure does not compensate for a pressure drop in the system due to leaks, faulty piping, or choked filters. Install a pressure regulator for better control. It’s also important to calibrate your pressure gauges at quarterly intervals.

2. CHANGE FILTERS ON TIME
   While replacing air filters is mandatory to maintain the quality of air, it is also an energy saving opportunity. Delaying an air filter change costs you more than you think! Clogged filters can lead to pressure drops and hamper efficiency. Ensure on-time service for a healthy compressed air system.

3. INVEST IN PRE-FILTERS
   Not only do pre-filters (also known as coalescing filters) help purify air by removing oil and water but also particulate matter to a certain extent. Installing pre-filters for suction air and cooling air can extend the life of your compressor and its consumables.

4. CLEAN UP
   Besides keeping your air clean, ensure that you give your compressed air system a thorough dusting every few months. Presence of sludge, dust or grime can have a big impact on the efficiency of the compressed air system. Pay special attention to compressor coolers and heat exchangers. Consider investing in a dedicated low pressure air compressor and air line for cleaning to save power.

5. PICK THE RIGHT DRYER
   Selection of the right sized air dryer for your compressed air system is crucial. Make sure the energy consumption of the dryer is in proportion to the demand. An oversized dryer can add to your electricity bill significantly.

6. CONSIDER A VFD
   Screw compressors should run under full load.
   If the usage pattern varies, consider a Variable Frequency Drive (VFD) for upto 35% reduction in energy cost. A VFD helps regulate the energy consumption based on demand fluctuations, ensuring energy efficiency. ELGi’s VFD has helped clients realize up to 215% savings in maintenance and energy cost with payback as low as 7 months.

7. PERFORM QUARTERLY MAINTENANCE CHECKS
   The importance of maintenance cannot be overemphasized.
   Regular maintenance can help you identify and accurately measure leaks in the circuit. They also reduce the chances of breakdowns leading to maximum uptime and productivity.

8. PREVENT MISUSE OF AIR
   Wasted air is wasted money. Invest time and money in training employees for efficient compressed air management. Create maintenance logs and update them on a regular basis, recording abnormalities or leaks in the systems. Systematically label leaks with proper tagging and prioritize repairs and plugging of leaks.

9. RECOVER HEAT
   It’s common knowledge that heat is produced during the process of air compression. If not used judiciously, all the heat energy goes to waste. Over 90% of the heat produced can be recovered and utilized for heating air or water at the facility.

10. GET AN AIR AUDIT
    Air audits enable companies to work with experts in the field and get valuable insights into their plant’s compressed air utilization. ELGi’s air audits chart out a customized and comprehensive energy management plan for your needs. Over the years, we have helped save millions of dollars in energy costs. Request an air audit now: http://www.elgi.com/contact-us/

In talks with Managing Director, Dr. Jairam Varadaraj, The Textile Magazine unearths the determinants of ELGi’s powerful claim in the compressed air business –– “we provide the lowest lifecycle cost in the world.”

In Part One, we followed ELGi’s evolutionary journey in manufacturing and design which makes a compelling case for sales of their air compressors. But ELGi’s approach to after-sales service is what makes them valuable partners for customers in the long-term.

Commenting on ELGi’s relationship with the Indian textile sector, Dr. Jairam Varadaraj said: “As a group we know textiles better than our competitors. This is because we have our own spinning mill in the group. We have been in the business of textiles for 40-odd years now. We know the pain points and challenges. Plus, we are based out of Coimbatore, a premier textile hub. Wherever you go across the country, people in the textile industry know ELGi.”

The company has a strong sales and service network spanning the length and breadth of the country. ELGi has an extensive team of more than 500 sales and service personnel with a maximum response time of eight hours. Elaborating on this, Dr. Varadaraj pointed out: “For us it is not just about responding when a customer calls. It is about restoring air. Today 96-97% of our customers get their air back in less than six hours. That’s a record nobody can beat. In fact, even our competitors acknowledge this strength of ours. We deliver uptime.

Generally we are there in about an hour. That’s the physical infrastructure. We also have a strong system in place where every defect, however small it may be, is registered at the factory by evening. We are also coming out with a SIM card based device which is incorporated in our compressors. It is in the testing phase. While others have also been offering similar services, we are doing it with a difference. The device talks to the compressor and gives a comprehensive performance report through an algorithm. The software then starts predicting. See, any mechanical device will degrade with wear. Failure takes place when you don’t notice this wear. With this monitoring, you will be able to get there before the failure. Predictive maintenance is what we offer. We have supplied about 55 machines with the device. By the end of this year, we will make it standard on all our machines. Many of our competitors offer it usually for large machines and invariably tied up with a service contract. We don’t want to follow that path. We firmly believe that the device is meant for us. More than our customers, we want to know how our machines are performing, for it will help us keep improving and stay ahead of the curve.”

ELGi caters to many industries. How prominent is the drilling and mining segment for you?

ELGi holds significant market share in India in the Drilling and Mining Segments.  ELGi caters to drilling applications such as Coal, Blue Metal, Granite, Marble, Sandstone and Limestone.  

How much does Rajasthan Market contribute to the overall business in India under the mining segment?

While we would prefer to not disclose numbers, Rajasthan contributes significantly to our mining business in India.

Describe features of 550-200 compressors

ELGi’s PG 550-200 diesel powered two wheel trolley mounted compressors guarantee optimal performance in the toughest working conditions with best-in-class fuel economy. The combination of a lightweight package and a compact footprint provides maximum maneuverability and allows for a  short turning radius.  

ELGi’s unique ηV profile screw element combined with PTFE 3-lip seal, optimum tip speed, precision machined castings and ground rotors ensure compressor longevity without compromising on efficiency. It’s compact design provides easy access to the compressor components for service and maintenance. The maintenance cost of this compressor is 50% lower than the competition.

Tell us about ELGi’s after-sales service support

Commitment to customers is one of ELGi’s strongest driving forces. ELGi’s customer care center operates 6 days a week, from Mon to Sat (08:00 am to 09:30 pm).

Customers can contact ELGi through the dedicated customer care number (1800-425-3544) or by sending an email (customercare@elgi.com) or by sending a text message to (+ 91 9282111224) for registering service requests. Our well qualified engineers attend to our customers’ needs within 48 hours. ELGi Customer Care is an integrated in-house system that provides an edge to ELGi’s  after sales capabilities.