AUTOMATION SOLUTIONS CASE STUDIES
Energy Monitoring System (EMS) Implementation
How We Helped Optimize Energy Usage and Cut Costs…
The Challenge:
A leading textile manufacturer was struggling with inefficient energy monitoring. Their outdated system lacked real-time visibility, leading to:
🚨 Unnecessary energy consumption and high costs
📉 No data-driven insights to optimize energy usage
🛠️ Difficulty in troubleshooting and identifying inefficiencies
🔎Goal: Implement an advanced, cost-effective Energy Monitoring System (EMS) to gain real-time insights and reduce operational costs.
Our Smart Solution: A Better, More Affordable HMI
We deployed a state-of-the-art EMS, tailored to their specific needs, offering:
✅Live energy monitoring across key production units
✅Data analytics integration for actionable insights
✅User-friendly dashboards to track usage and identify inefficiencies
✅Automated alerts for abnormal consumption patterns
How We Did It??
🔹 Step 1: Assessed current energy monitoring gaps and inefficiencies.
🔹 Step 2: Designed a custom EMS integrating IoT sensors and smart meters.
🔹 Step 3: Installed real-time data tracking & analytics dashboards.
🔹 Step 4: Trained the team to leverage insights for continuous optimization.
🚀Total Implementation Time? Just 3 Days!
The Results: Big Savings & Better Performance
💰 Cost Savings: Significant reduction in unnecessary energy expenses
📊 Improved Efficiency: Real-time tracking enabled proactive decision-making
⚡ Optimized Usage: Identified and eliminated energy wastage
🔄 Seamless Integration: Easy adoption with existing systems
Ready to Cut Your Energy Costs?
Take control of your energy usage and maximize efficiency with our cutting-edge EMS solutions. Contact us today and start saving!
MOISTURE CONTROL SYSTEM REPLACEMENT OF FINISHING MACHINE
How We Helped Our Client Save Upto 83% Cost…
The Challenge:
Artistic Fabric Mills (AFM-07) faced a serious problem: their MAHLO Moisture Control System on the finishing machine had failed.
🚨 Impact: The machine was completely non-operational, leading to major daily production losses.
💡 Goal: Find a cost-effective solution that restored machine functionality while ensuring fabric quality remained as high as before.
Our Smart Solution:
Instead of opting for an expensive MAHLO replacement, we designed and installed a custom Moisture Control System using advanced PLC technology. The results?
✅83% cost savings compared to a MAHLO system
✅Fabric quality guaranteed to match the original
✅1-year warranty for peace of mind
How We Did It??
🔹 Step 1: Assessed the finishing machine and confirmed feasibility.
🔹 Step 2: Designed and installed a custom Moisture Control System tailored to their needs.
🔹 Step 3: Tested and verified the system to ensure top performance.
The Results: Big Savings & Better Performance
💰 Massive Savings: 83% reduction in costs
📈 Reliable Performance: Matching OEM’s Quality in Production
🔄 Peace of Mind: 1-year hardware warranty included plus 1 month checking warranty of Breakneck’s program.
Want a Smarter Moisture Control Solution?
Stop overpaying for expensive replacements! Contact us today for a cost-effective, high-performance solution for your machines!
DESIGN OF HUMIDIFICATION PLANT
How We Helped Indigo Textile Save 50% on Costs & Cut Energy Use by 20%
The Challenge:
Indigo Textile Pvt. Ltd. faced a critical problem: their humidification plant for weaving had malfunctioned. The original control system was outdated and no longer available.
🚨 Impact: The entire weaving plant was shut down, leading to major production losses.
💡 Goal: Find a cost-effective solution that restored plant functionality without replacing the entire system.
Our Smart Solution:
Instead of a costly full replacement, we designed a custom PLC & HMI-based control system and integrated a Variable Frequency Drive (VFD) at the showering pump to boost efficiency. The results?
✅50% cost savings compared to a full system replacement
✅20% energy savings through VFD installation
✅Precise temperature & humidity control for consistent fabric quality
How We Did It??
🔹 Step 1: Conducted a site visit to assess system compatibility.
🔹 Step 2: Designed and developed a new PLC & HMI control system.
🔹 Step 3: Removed the outdated AIR PLUS humidification controller & shower line actuator.
🔹 Step 4: Installed and commissioned the new control system & VFD at the showering pump.
The Results: Big Savings & Better Performance
💰 Massive Savings: 50% reduction in costs
⚡ Energy Efficiency: 20% reduction in electricity usage
📈 Reliable Performance: Maintained consistent temperature & humidity
Want to Optimize Your Plant & Save Big?
Stop overspending on outdated systems! Contact us today for a cost-effective, high-performance solution tailored to your needs!