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 

One of Egypt’s leading emulsion polymers’ producers was seeking a robust and reliable air compressing solution for constant air supply with variable pressure compression. That’s when they adopted ELGi’s eco-friendly, energy-efficient EG Series Screw air compressors to increase reliability and ease of use at its manufacturing operations. 

According to reports, the polymer emulsion’s market size is expected to rise from USD 25.2 bn in 2020 to USD 38.1 bn by 2025.1 Despite the shock from COVID-19, considered unparalleled since the great depression and the IMF warning of an uneven slump ahead, the growth prediction of 8.6% CAGR is heartening for all stakeholders. 

The prediction is based on solid fundamentals and is not just a result of biased speculation. Market growth is driven by regulatory mandates, emerging energy disruptions, shifting consumer dynamics, and growing end-user industries, principally from emerging countries. 

Strict regulations are fuelling product demand. Stringent pro-environment guidelines around toxic chemical emissions and directives regarding the usage of water-based emulsion polymers over synthetic products. Various end-user industries like paper, textile, and consumer durables are adopting polymer emulsion to control noxious emissions. Additionally, the auto industry, coupled with the construction industry, is driving the global polymer emulsion market. Owing to a growing demand for green buildings, the global construction market is poised to grow by 85% to $15.5 trillion worldwide by 2030.² 

The Polymerisation Process 

Often called ‘products by process,’ emulsion polymers signify that the composition of the bulk polymer is as important as the process of making it.  

Alcohol is an emulsifying and dispersing agent for paper coating, board coating, water-soluble film, textile sizing agent, paper and wood adhesive, release liners and carpet coating among others.     

The emulsion polymer manufacturing process is very complicated. 

With traditional energy-guzzling installations, mounting pressure loss increased startling load, and rigidity in temperature compromising air quality, the need was for advanced air compressors with high-end design and advanced features. The company was seeking a partner to help deploy compressed air systems that can withstand the harshest of environmental conditions while saving energy, costs, and reducing Co2 emissions. 

From 2018, the company started leveraging ELGi’s total compressed air solutions to achieve best-in-class energy efficiency.  

ELGi’s eco-friendly, energy-efficient EG Series Screw Compressors delivered constant air supply with variable pressure compression. Through its in-house, proprietary η-V profile rotors designed to run at optimum speeds, it reduced pressure losses and increased efficiency. ELGi’s 1000 litre high-pressure air receiver, designed to ASME standards and built-in ELGi’s dedicated facility, acted as an enabler between the compressor and the variable pressure caused by demand waves helping reduce the loading and unloading cycle pressure on the compressor. 

Airtime refrigeration, air dryers, and filters prevented real-life problems like unwanted abrasive sludge, corrosion of piping, and erosion of pneumatic tools.  

ELGi’s Airtime refrigerated air dryer has ensured longer life of compressed air system through the efficient removal of the condensate and contaminants. As per international protocol, ELGi uses ozone-friendly R 134A gas as the refrigerant which has zero ozone-depletion potential. 

The organisation specifically selected the ELGi EG Series compressor on account of its following features and benefits: 

• Reduced startling load: The new generation intake valve system is designed for low losses. 
• Moisture-free air: The EG Series air compressor, with its custom-designed centrifugal type moisture separator and automatic drain, removed over 99% of bulk water from the compressed air. 
• Cool air: Efficient air cooling from an integrated fan-motor maintains a low temperature, resulting in the increased lifespan of the motor.  
• Robustness and reliability: Designed to perform in extreme temperatures, the compressors have performed well in cold, hot, and humid, as well as arid conditions.     

CONCLUSION 

The partnership with ELGi has enabled the organisation to address various operational requirements, including the need for clean, moisture-free, oil-less (1ppm) air that is free of other contaminants as well. The emulsion polymer maker has also been able to reduce the life cycle costs for its air compressors, besides realising significant energy savings and uptime warranty. 

To know more about our offerings in the manufacturing sector, do reach out to us at communications@elgi.com or call us 1800-203-3544 (Toll-free, India). 

1. Polymer Emulsion Market worth $38.1 billion by 2025 – Exclusive Report byMarketsandMarkets™

https://www.prnewswire.com/news-releases/polymer-emulsion-market-worth-38-1-billion-by-2025–exclusive-report-by-marketsandmarkets-301124978.html 

2. Global Construction Market to Grow $8 Trillion by 2030: Driven by China,USand India 

https://www.prnewswire.com/news-releases/global-construction-market-to-grow-8-trillion-by-2030-driven-by-china-us-and-india-544142522.html 

In our fight against the Coronavirus, PPE products have become an essential requirement for the protection of every individual at the frontline, from doctors & medical staff, to policemen, cleaning staff and security & delivery personnel.

Textile units have started allocating their resources towards the production of such protective gear, adjusting to the needs of a changing world.

During the 19^thcentury, this tough cotton twill fabric with an indigo warp and weft was commonly used to tailor trousers for sailors from Genoa, Italy. Levi Strauss is credited as the co-founder of the blue jean, created in 1873 in the aftermath of the California Gold Rush. Nevada tailor Jacob Davis and Levi Strauss filed for patent numbers 139 and 121 for the first rivet-reinforced denim jeans. These denims would then go on to be used as standardised sturdy uniforms for miners, farmers and mechanics.

The Past

Established in 1960 in Coimbatore, India, ELGi started off as an air compressor and a garage equipment manufacturing company. Over the years, with strategic collaborations and a relentless focus on research and development, ELGi has made remarkable progress from an importer of technology to a self-reliant manufacturer of compressed air systems.

Throwing some more light on ELGi’s growth story, Dr. Varadaraj stated: “We started like everyone else. Indian companies went to Europe or America and got licenses from top companies. When you get the license, you invariably get post-generational technology. No one will give you the latest one. They will give you the ‘know-how’, meaning they will give you a set of drawings and say this is how you assemble the machine. However they will never tell you ‘why’. As a result, you become a constant slave to imported technology. When we started out in 1994, India was just opening up. We knew that if we go the licensing way, we will reach nowhere. We therefore had to build our own technology. We chose the harder path. From 1994 onwards we have been investing in R&D and latest technology. We learnt the ‘know-why’. We have also learnt the shifts that are taking place. Additionally, we have also learnt the direction of the shift. If you understand the shift and only respond to it, you are a follower. It is only when you learn to preempt the direction of the shift that you become a leader. You can say that we are now at the cusp of being able to lead with the next generation of air compressors.”

The Present

ELGi’s ‘know-why’ attitude has led to the development of some of the most technologically evolved air compressors of our time. Global leadership seems like the logical next step. But before that, ELGi must jump through many proverbial hoops. Debunking myths and preconceived notions about ELGi remains one of the most formidable challenges for the company.

“We have enough evidence to prove that we are at par or better than the best, but that doesn’t mean we are close to what we intend to achieve. Remember the odds that were stacked up against us. For one, ELGi was a relatively unknown brand in international markets. Then there’s always this stigma of a “Made in India” label, which I feel is more of a perception than anything else. It is a perception though, which is gradually changing. So, with all these limitations, in order to be competitive in these markets, being marginally better is not good enough. So that’s really what we are driving at. Customers in these markets can be unforgiving. And if it is an Indian brand, then the forgiveness quotient is even less,” observed Dr. Varadaraj.

Specifically in the Indian market, there is a general view prevailing that the company’s thrust on the textile industry has not been aggressive enough. Competitors have been relatively more direct and assertive about their capabilities.

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.”