SEE-Tech Solutions carried out an investment-grade energy audit for a large plastic injection moulding manufacturing facility operating multiple high-capacity injection moulding machines supported by energy-intensive utility systems. The objective of the engagement was to identify measurable energy-saving opportunities, reduce operating costs, and develop a clear, prioritized implementation roadmap without affecting production quality, machine reliability, or throughput.

The facility operates on a continuous production model, with energy consumption dominated by injection moulding machines, hot air dryers, dehumidifiers, compressors, chillers, and HVAC systems. Electricity accounted for a major portion of operating expenses, making energy efficiency a strategic business requirement rather than just a compliance activity.

4

Process & Energy Challenges

Detailed site measurements, data logging, and system analysis revealed several key inefficiencies:

• High electricity consumption from Husky injection moulding machines and dryers

• Significant heat loss from hot air dryer exhaust and machine heating zones

• Under-loaded motors operating far below optimal efficiency

• Moisture recirculation on the shop floor increasing dehumidifier energy demand

• Inefficient cooling methods adding humidity instead of removing it

• Elevated compressor energy consumption due to high suction air temperature

• Lack of coordinated control between utilities and production load variations

These issues resulted in avoidable energy wastage, higher production costs, and increased carbon emissions.

4

SEE-Tech Solutions Approach

SEE-Tech Solutions adopted a system-level, data-driven audit methodology, covering:

• Injection moulding machines and auxiliaries

• Hot air dryers and dehumidification systems

• HVAC and air washer systems

• Air compressors and compressed air distribution

• Chillers, cooling towers, and pumping systems

Each system was evaluated based on actual operating conditions, not nameplate ratings. Energy Conservation Measures (ECMs) were developed with measured data, savings calculations, investment estimates, and payback periods.

Key solutions included:

• Heat recovery from hot air dryers using air-to-air heat exchangers

• Replacement of standard motors with IE5 ultra-efficiency motors combined with VFD control

• Improved insulation for machine barrels, heaters, and material transfer hoses

• Dehumidifier optimization using dew-point-based automation and moisture isolation

• Replacement of direct evaporative cooling with indirect evaporative air washers

• Cycle-time optimization in moulding machines to reduce specific energy consumption

• Pre-cooling of compressor suction air using chilled water

• Utility system optimization for chillers, pumps, and cooling towers

4

Utility & Environmental Improvements

By reducing unnecessary moisture addition and optimizing airflow and cooling strategies, the facility achieved:

• Lower dehumidifier load and stable humidity control

• Reduced HVAC energy consumption

• Improved shop-floor working conditions

• Better process stability for injection moulding operations

The optimized systems were designed to adapt automatically to production load changes, ensuring sustained energy savings.

4

Results & Business Impact

The energy audit identified nine high-impact projects delivering:

• ~10% reduction in overall plant energy consumption

• Over 52 lakh kWh of annual electricity savings

• ₹2.6+ crore per year in energy cost reduction

• ~4,000+ tons of CO₂ emission reduction annually

• Project payback periods ranging from 4 months to 36 months

• Improved equipment reliability and reduced maintenance stress

• Increased production efficiency through optimized cycle times

A 12–18 month phased implementation roadmap was provided, enabling the client to prioritize quick-return projects while planning capital investments strategically.

Conclusion

This project highlights SEE-Tech Solutions’ expertise in delivering investment-grade energy audits for complex manufacturing environments. By combining deep process understanding, advanced technologies, and execution-ready solutions, SEE-Tech enabled the facility to achieve measurable cost savings, enhanced productivity, and long-term sustainability—without compromising operational performance.