Client & context
Closed-die forging unit, three screw compressors feeding pneumatic die cushions and tool changers.
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Asset efficiency
Forging: compressor unload and leak load
Three ageing compressors ran continuous unload cycles between hammer strokes, 12% of plant kWh with no production benefit.
−12%
Compressor SEC
−35%
Unload hours
₹2–5L
Monthly savings
The challenge
Compressors were sized for peak stroke demand but ran unloaded 60% of shift time. Leak load was never isolated from production demand.
Our approach
Instrumented compressor run hours vs hammer stroke timestamps.
Ranked leak vs unload waste by rupee impact per shift.
Prescribed unload timer adjustments and maintenance windows for highest-leak headers.
Outcomes
12% reduction in compressor-specific energy consumption.
35% fewer unload hours per shift after timer and header maintenance prescriptions.
₹2–5L monthly savings at reference tariff.
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