1. Key Challenge
The business was operating a 50 HP compressed air system that drove high energy costs and a considerable volume of CO₂ emissions.
With an annual consumption of 301,344 kWh and an associated cost of $653,916.5 MXN, the company required an efficient solution to reduce energy spending and improve environmental sustainability.
2. Implemented Solution
Saving with Energy Mexico carried out the first segment of Phase 2 through a detailed analysis of compressed air consumption and demand. Based on the findings, a 20 HP compressor was identified as the optimal choice to improve system performance. Implementation of the new compressor included:
- Replacement of the 50 HP compressor with a 20 HP unit.
- Monitoring and adjustment of actual compressed air demand.
- Implementation of a maintenance plan to maximize efficiency.
3. Results
The initial corrections completed in Phase 2—specifically the implementation of the 20 HP compressor—delivered significant improvements:
- Reduction in Electrical Energy Consumption: 131,400 kWh annually.
- Energy Cost Savings: $285,138 MXN (15,947.3 USD).
- Capacity Cost Savings: $108,645 MXN (6,076.3 USD).
- CO₂ Emissions Reduction: 95 tons annually.
- Total Energy Cost Savings: $393,783 MXN (22,023.7 USD).
- Return on Investment: 1.2 years.
4. Conclusion
Thanks to the Always-On-Time Maintenance Plan (PMST), a comprehensive analysis was carried out, which led to the implementation of a 20 HP compressor. This solution enabled Halyard to significantly reduce its energy costs and environmental impact.
As a result, the company improved its operational efficiency and optimized resource allocation, achieving a return on investment in just 1.2 years. This success story underscores the importance of aligning energy infrastructure with actual demand, ensuring the right balance between cost savings and sustainability.