In continuous cable manufacturing, compressed air performance must keep pace with constantly changing production demands. In a leading cable manufacturing facility, compressed air plays a critical role across extrusion controls, air-wipe drying, cleaning, and material handling systems, making pressure stability and compressor reliability essential for consistent product quality and... high uptime. At the plant, a 75 kW fixed-speed compressor reliably met base air requirements. However, variations in production loads, line speeds, and process cycles led to frequent demand fluctuations, resulting in repeated compressor cycling, higher energy consumption, and pressure instability across the system. With the deployment of ELGi’s DEMAND=MATCH System, performance was evaluated under actual operating conditions by comparing operations with and without DEMAND=MATCH. The results were clearly validated. • 11.1% reduction in average power consumption (from 69.9 kWh to 62.1 kWh per hour) • Approximately 1,489 units of energy saved over just eight days of actual running • Reduced load cycling, leading to improved pressure stability and lower mechanical stress on the compressor This deployment demonstrates how intelligent airflow control can deliver measurable gains in energy efficiency, system stability, and operational reliability, all critical in a continuous manufacturing environment. A strong example of how aligning compressed air delivery with real-time demand can drive sustainable performance improvements on the shopfloor. Learn more about how DEMAND=MATCH optimises compressed air systems:show more

Elgi Equipments Limited

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