Energy Savings with VFDs: A Case Study
This real-world case study demonstrates how a textile manufacturing plant in Surat, Gujarat achieved 35% energy savings by implementing Variable Frequency Drives (VFDs) on their industrial motors, with technical support from Tau Engineers, Ahmedabad.
Client Background
- Industry: Textile manufacturing
- Location: Surat, Gujarat
- Operation: 24/7 production
- Challenge: High energy costs from constant-speed motors running at full capacity
The VFD Solution
Before VFD Installation
- 10kW motors running at constant speed
- Excessive energy consumption during partial loads
- Mechanical throttling causing energy waste
- High maintenance costs due to constant stress
After VFD Installation
- Precise speed control based on actual demand
- Soft-start capability reducing mechanical stress
- Automatic adjustment to load variations
- Real-time monitoring of energy consumption
📞 Could your plant benefit from VFDs? Call our energy experts at +91 7990998834 for a free assessment
Technical Implementation
Motor Specifications
- Type: 10kW Three Phase Induction Motors
- Quantity: 7 motors (5 for fans, 2 for pumps)
- Operation Hours: 8,000 hours/year
VFD Configuration
- Model: VFD-7.5HP
- Features: PID control, built-in filters, harmonic mitigation
- Installation: Our technicians completed in 3 days
Energy Savings Analysis
Power Consumption Comparison
- Before: 5,60,000 kWh/year (7 motors × 10kW × 8,000 hrs)
- After: 3,64,250 kWh/year (35% reduction)
- Savings: 1,96,000 kWh/year
Financial Impact
- Electricity Rate: ₹10/kWh (industrial tariff)
- Annual Savings: ₹1,96,000
- Investment: ₹2,10,000 (including installation)
- Payback: 14 months
Key Insight: The highest savings came from fan applications (42% reduction) where airflow requirements vary significantly throughout production cycles. Pump applications showed 28% savings.
Additional Benefits Realized
1. Equipment Longevity
- Reduced mechanical stress from soft starts
- 50% decrease in bearing replacements
2. Improved Process Control
- Precise speed adjustment for different fabrics
- Better temperature and humidity control
3. Maintenance Reduction
- Fewer motor rewinds needed
- Reduced conveyor belt wear
📧 Get a free VFD savings estimate for your facility
Email info@tauengineers.in with your motor details
Serving industries across Gujarat, Maharashtra, Tamil Nadu, Delhi NCR and nationwide
Our VFD Solutions
At Tau Engineers, we provide complete VFD solutions:
- ✅ VFD Selection Guidance - Right-sized for your application
- ✅ Professional Installation - Certified technicians
- ✅ Parameter Optimization - Tailored to your process needs
- ✅ Ongoing Support - Maintenance and troubleshooting