Web Exclusive | August 2014
Atlas Copco compressors help spinner save energy
In the Primayudha Mandirijaya Pt textile factory in Indonesia, an Atlas Copco ZH 350+ centrifugal compressor supplies oil-free air for production processes throughout the facility. As the factory has become more automated, the use of high quality compressed air has increased substantially.
Established in 1996, Primayudha Mandirijaya Pt. started the commercial production of yarn in 1998. The company has a 50-acre factory in Desa Ngadirojo Boyolali in Central Java with approximately 1,200 employees. The factory has a production capacity between 95,000 and 120,000 bales of yarn per year.
In 2012, Primayudha Mandirijaya Pt. bought an Atlas Copco ZH 350+ centrifugal air compressor with 7 bar pressure and 350 kW to control the valves and cylinders for its spinning and winding processes. On the winding machine, compressed air is used to splice yarn, and the air-jet loom requires compressed air for the insertion of weft. Compressed air is also needed during the weaving process.
High quality air is essential in integrated textile units. Atlas Copco was the first manufacturer to provide the textile industry with energy-efficient and reliable oil-free compressed air solutions that allow yarn production at a relatively high rate.
“Constant pressure is the most important element in our factory,” said Mukesh Garg, Production Manager for Primayudha Mandirijaya Pt. “Before we purchased the compressor, we compared different brands of products and learned that only Atlas Copco centrifugal compressors satisfy our demands for pressure and provide us with high productivity.”
ZH 350+ oil-free centrifugal compressor eliminates risks: During the air-jet spinning process, cotton is spun into yarn with compressed air supplied through fine nozzles. Oil in the compressed air can clog the nozzles and stain the yarn, which is in direct contact with the compressed air. Expensive nozzle replacements, production losses and rejection of the product by the customer can result.
Atlas Copco’s ZH 350+ oil-free centrifugal compressor provides Primayudha Mandirijaya Pt. with 100% pure, clean air that complies with ISO 8573-1 Class 0 (2010) certification. Class 0 means zero risk of contamination; zero risk of damaged or unsafe products; and zero risk of losses from operational downtime.
“To protect our reputation and product quality, we had to select a reliable and oil-free machine to support our production process,” said Mukesh Garg. “Atlas Copco’s centrifugal air compressor ZH 350+ has shown a very good performance.
As a testament to their trust in Atlas Copco compressors, Primayudha Mandirijaya Pt purchased another Atlas Copco unit – a ZH 500+-9 centrifugal compressor – in November 2013. Delivered as a plug-and-play package, the ZH 500+-9 employs advanced aerodynamics to reduce energy consumption in the core and reduce pressure drop from cooler, inlet filter and optimised part design. It saves up to 7% on specific energy at full load and up to an additional 9% at partial load.
The new machine arrived at Primayudha Mandirijaya Pt. in April 2014. “We hope this new machine will help us to increase our production reliability, safeguard the quality of our product, and also achieve maximum energy savings,” said Garg.
Huge energy saving by automotive textile unit
Automotive textile manufacturer Autofil Worldwide has achieved average cost savings of £ 37,000 a year and reduced annual CO2 emissions by 260,000 tonnes by adopting Atlas Copco’s energy recovery technology.
Based in Sherwood Park, Nottingham, UK, Autofil Worldwide is one of Europe’s leading manufacturers and suppliers of polyester yarns for the automotive sector. By recovering heat produced by the air compressor used in the manufacturing process, the compa