case studies

Indian textile manufacturers Sri Ramco Spinners and Rajapalayam Spintext are cuttingdown energy expenses by utilising Danfoss VLT® frequency converters for humidifiercontrol.

Humidification the Cost-Saving Way - VLT® DRIVES - CASE STORY
 
Customer background : 

The Ramco Group of Industries Ltd at a Glance.
The Ramco Group started out in 1938 as a cotton spinning mill in Rajapalayam, India. 
Today the company makes up an industrial group of 20 units mills, supplemented with a number of plants primarily within the building material industry in India and abroad. 
 
The Ramco Group of Industries is a market leader when it comes to quality and price. The annual turnover amounts to approximately 230 million US$, brought about by some 19,000 employees. They benefit from a modern manpower policy, ensuring them wages above average, housing, pension, supplementary education etc.
 
 
Application details : 

Substantial energy savings and increased product quality at a short payback time. Those were the three main reasons for cotton spinning mill Sri Ramco Spinners and Rajapalayam Spintext domiciled in the South Indian town Rajapalayam, to install Danfoss VLT® frequency converters at a humidification plant in their factories.The starting point was a plant with maximum capacity based on peak summer requirements. This capacity was employed throughout the year, irrespective of the requirement for humidification. Correspondingly, the energy consumption was constant, whether on a hot and dry summer day or a cold and rainy winter day. This wintertime over-capacity was until recently throttled by dampers - a simple and efficient technology, yet expensive in operation: dampers and valves do not change the speed of fans and pumps, but merely make up a cork in the bottle,so to speak. Consequently, fans and pumps are running much too fast during the winter - using costly energy of no use of approximately 2.5 years. So Mr. Madhavan gave the go-ahead to the installation in other plants also after getting green signal from Top Management.
 
 
" Lay-out of humidity control system. The three VLT® frequency converters communicate with the HUMICON controller which calculates the speed of the fans and the pump based on actual temperature and humidity measurements. The controller communicates with the frequency converters using the RS 485 interface."
 
Improved air quality and more than 25%
 
Energy savings : 

After being put into operation the new humidifier control system has turned out even more promising, more than 25% energy savings has lowered the payback time to 2 years - a critical issue when you are subject to high rates of interest and operating in a volatile market.
 
On top of the energy savings Rajapalayam Spintext has also noticed an improvement of the air quality in the spinning mill. Its temperature and humidity are more stable than can be obtained with dampers (see fig. 2), an important issue for Rajapalayam Spintext who export all their products to the highly quality conscious Japanese market. 
 
Mr. Murugan .S, Assistant factory Manager is very much satisfied with the performance of the renewed humidifier, even though the good results have not taken him by surprise: “We have known the VLT® frequency converters 4-5 years from the spinning process where they control our carding machines, speed frames and ring frames. In fact we have more than 100 installed. That is another reason we felt confident when choosing Danfoss for the humidifier.”
 
Easy installation : 
 
Mr. Murugan . S mentions easy  installation on existing plants as a strong point of the new control system: 
“We did not have to change the humidifier in any way. All we needed was to connect the temperature and humidity sensors and the RS 485 serial communication cable,” the Assistant factory Manager explains.”
 
Tangible Benefits : 
 
Installing humidification plant controls featuring VLT® frequency converters from Danfoss has brought about the following benefits for Sri Ramco Spinners and Rajapalyam Spintext.”
  • More than 25% energy savings.
  • A more accurate humidity level.
  • Increased system reliability.
  • Better air flow control.
  • Pay back in less than two years.

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