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Results

Measured on the customer's own sensors. Read against the Systel Audit Archive.

Every figure below is from a plant on the programme, read from its dashboard against its measured baseline. Names and logos appear only with the customer's written approval.

Textiles · spinning3-unit spinning group, Tamil Nadu0.189 → 0.162 kW/CFM Textiles · spinning · published100,000-spindle mill, Tamil Nadu1,300 → 560 CFM · payback under six months Textiles · home textilesIntegrated plant, GujaratFlagship project · baseline under way Tyres and rubber[Pending approval]Dew-point compliance · curing lines
Case study · Textiles · spinning

A 3-unit spinning group in Tamil Nadu: specific power 0.189 → 0.162 kW/CFM in nine months — with no new compressor.

Plant 1,400 kW installed · 4 compressors · 3 units · 24×7Deployed 11 flow · 6 power · 5 pressure · 4 dew pointPeriod Jan – Sep 2026
METRICMEASURED BASELINE · JANVERIFIED · SEPCHANGE
Specific power0.189 kW/CFM0.162 kW/CFM−14%
Non-productive air share31% of capacity9%−22 pts
Pressure drop across treatment0.58 bar0.32 bar−0.26 bar
Energy below baseline—1,270 kWh/daymeasured
Avoided emissions, Jan – Sep—[__] t CO₂for ESG reporting
All figures read from the plant's own WiseAir sensors on the WASM 604 dashboard. Client name withheld until written approval.
The problem, in the owner's words

"Our compressed-air bill went up every year and every supplier told us to buy a bigger compressor. We had no way to check."

What the sensors showed
  • Non-productive air 31% of capacity, concentrated in the autoconer section
  • Header at 7.4 bar against a 6.6 bar requirement at the farthest machine
  • Dryer 2 at +9 °C pressure dew point, afternoons only
  • One 75 kW compressor unloaded 6–8 hours a day
What Systel read into it: the dryer was overloaded by a 41 °C inlet, not faulty — no desiccant unit needed. The autoconer loss was splicers, the pattern we see in nine spinning mills out of ten. The unloaded compressor was a set-point overlap. Order of work: sequencing, splicers, set-point, then the dryer intake.
What the plant's team did
  • Resequenced the compressors — a two-hour job
  • Two splicer-and-leak campaigns with its own fitters, verified on night-time flow
  • Header set-point stepped down 0.2 bar a week to 6.8 bar
  • Shaded the dryer intake; dew-point alarm set at +3 °C
Systel measured, prioritised and tracked each item. The plant carried them out.
Specific power by month, kW/CFM
0.189 → 0.162 kW/CFM | 1,270 kWh/day | ₹28.6 L in nine months. Two-thirds of the gain came from sequencing and splicers in the first eight weeks; the rest from pressure. June (amber) was a C1 service month, above trend, as expected.
Actions tracked
URGENTCompressor sequencing overlapClosed Jan
HIGHSplicer and leak campaign 1 — 142 points, autoconersClosed Mar
HIGHHeader set-point 7.4 → 6.8 barClosed May
MEDIUMZero-loss drains on receivers 1–3Open · ₹[__]/mo

"Every supplier told us to buy a bigger compressor. Systel looked at the dashboard for ten minutes and told us to change the splicers. They were right."

[Name], Managing Director · [Group] — pending written approval
Case study · Textiles · spinning · on the programme since 2019

The compressors said 0.16 kW/CFM. The sensors said 0.196.

A 100,000-spindle mill in Tamil Nadu ran two screw compressors, 850 and 450 CFM, 132 and 75 kW, at a paper specific energy of 0.16 kW/CFM. The plant wanted to get from about 1,300 CFM to 600 and did not know where to begin.

The monitoring system showed the pair delivering 1,120 CFM for about 220 kW: 0.196 kW/CFM, 18% worse than claimed. Spinning and autoconer were drawing 800 CFM against a need of about 300; preparatory 320 against 50. The archive had seen both patterns before: artificial demand from over-set machine pressures, and leaks that returned after every survey.

0.196 → 0.17kW/CFM after supply-side settings and maintenance · 537 kWh/day
1,300 → 560CFM, two years after the project — below the 620 CFM reached at hand-over
< 6 monthspayback on the digitization project and monitoring system
What the plant's team did, from the daily readings
  • Reset machine operating pressures in spinning, autoconer and preparatory — about 150 CFM of artificial demand removed
  • Fixed leaks department by department, watching each department's daily consumption instead of waiting for the next survey — about 350 CFM
  • Adjusted compressor inlet, ambient and set-point conditions and carried out the maintenance the readings pointed to
  • Avoided the large spares earlier leak-survey agencies had recommended — spares spend down by about 60%
Annual savings reported by the mill: ₹12.56 lakh on the supply side and ₹47.73 lakh on the demand side at ₹6.5/kWh. Already published on systel.asia; figures as reported by the plant.

"14% reduction in compressor energy consumption. 10,368 kWh saved per day after installing Systel's smart online compressed-air monitoring system."

G. Mahendran, Senior Manager – Utility, JSW Steel Ltd — testimonial already published on systel.asia; re-confirm approval before relaunch

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