1. Key Challenge
The company was facing significant energy challenges that impacted both its operating costs and sustainability goals.
On one hand, it experienced high energy consumption and emissions caused by an inefficient compressed air system. On the other, persistent leaks were detected in its air network, further aggravating energy waste and driving up annual expenses.
2. Implemented Solution
Saving With Energy Mexico executed a comprehensive strategy divided into two stages:
1: Energy Demand Analysis and System Sizing
Remote monitoring was implemented to assess compressor performance and propose a tailored solution:
- Replacement of inefficient units with variable speed compressors (RS75n or IRN100H-OF).
- Integration of the X8I intelligent sequencer to coordinate up to 8 compressors efficiently.
- System adjustment to match actual consumption, optimizing operation during peak hours.
2: Always-On-Time Maintenance Plan (PMST) and Leak Repair Program
A corrective and preventive plan was applied, focusing on leak detection and repair:
- Technical system diagnostics.
- Advanced leak detection and sealing techniques.
- Establishment of continuous monitoring.
3. Results
In just two corrective applications, the company achieved:
45% reduction in leak-related costs, equivalent to annual savings of $6,311.08 USD.
Decrease in energy consumption by 405,813 kWh per year, representing estimated savings of $64,648 USD.
Reduction of CO₂ emissions by 162 tons annually.
Decrease in energy demand from 355 kW to 319 kW, reducing capacity charges.
Return on investment between 1.5 and 3.4 years, depending on the equipment selected.
4. Conclusion
The combination of a detailed energy demand analysis and the PMST plan enabled the company to reduce costs, cut emissions, and enhance operational performance. This case demonstrates how a phased, data-driven strategy supported by technology can transform the energy efficiency of an industrial plant.
This business success story is just the beginning. The initial results reinforce SWEM’s focus in its upcoming phases: 1. Data measurement through remote monitoring. 2. Optimization and resource management with solutions tailored to operational realities, maintaining a clear commitment to sustainability and the UN Sustainable Development Goals (SDGs).