The process of making rubber tyres is extremely energy intensive and also requires a lot of water for cooling. Leading Indian tyre manufacturer MRF needed to improve production rates and was looking for ways to reduce running costs at its Trichy factory.
By understanding the limitations of existing plant and using fundamental engineering knowledge, specific recommendations were made to bring about efficiency savings. These included treating effluent for reuse in the factory and installing more efficient water cooling equipment to save 330m3 of water a day. Adaptation of the plant’s air compressor system to only supply air at the required pressures also yielded power savings of 650kW per day.
Annual savings of US$1M have been realised by installing equipment that operates more efficiently and economically. The savings and the way they have been made have really impressed MRF, which has appreciated the tailor-made solutions that also maximize the use of existing plant to further keep costs down. MRF’s confidence in the benefits of refurbishing or replacing equipment has increased. As a result, similar improvements are now being explored at other factories.