AUTO
Leading Auto Manufacturer
Automotive Plant, Chennai - CompMate Success Story
42%
Cost Reduction
₹7.5L
Annual Savings
16
Months Payback
The Challenge
The automotive manufacturer's Chennai manufacturing facility faced escalating energy costs for hot water generation across multiple applications:
- Paint Booth Operations: Continuous hot water requirement for cleaning and processes
- Employee Facilities: Hot water for canteens, restrooms, and changing areas
- Process Heating: Various manufacturing processes requiring heated water
- Seasonal Variations: Fluctuating demand throughout the year
Key Pain Points:
- • Annual hot water heating bill: ₹18 lakhs
- • High electricity consumption for water heating
- • Increasing energy costs impacting profitability
- • Need to meet corporate sustainability targets
Facility Overview
Industry: Automotive Manufacturing
Location: Chennai, Tamil Nadu
Plant Size: 50,000 sq ft
Air Compressors: 3 x 75kW Units
Operating Hours: 24/7 Production
Hot Water Demand: 15,000 L/day
The Promethean Solution
System Design: Promethean Energy installed 3 CompMate units on the facility's 75kW air compressors, strategically positioned to capture maximum waste heat.
Technical Specifications
- Heat Recovery Units: 3 x CompMate systems
- Heat Capture Capacity: 45 kW thermal
- Hot Water Output: 65°C continuous
- Storage Capacity: 2,000L insulated tanks
- Monitoring System: IoT-enabled real-time tracking
Installation Features
- Minimal Disruption: Installed during planned shutdown
- Retrofitted Design: No compressor modifications required
- Smart Controls: Automated temperature and flow management
- Safety Systems: Multiple fail-safes and monitoring
- Integration: Seamless connection to existing hot water distribution
Installation Process: The installation was completed over a planned 3-day shutdown period with minimal disruption to production operations. Our team worked closely with the plant's engineering staff to ensure seamless integration.
Outstanding Results
Energy Performance
Hot water heating cost reduction: 42%
Annual energy cost savings: ₹7.5L
Heat recovery efficiency: 85%
System uptime: 99.2%
Business Impact
Simple payback period: 16 months
CO₂ emissions reduced: 85 tonnes/year
Total project investment: ₹12L
10-year NPV: ₹45L
Additional Benefits
Environmental Impact
- • Contributes to corporate carbon neutrality goals
- • Reduced dependence on grid electricity
- • Enhanced sustainability reporting metrics
- • Alignment with green building certifications
Operational Excellence
- • Improved energy security and independence
- • Reduced maintenance requirements
- • Enhanced system reliability
- • Real-time performance monitoring
Strategic Value
- • Model for replication across other plants
- • Demonstrated commitment to innovation
- • Enhanced corporate reputation
- • Competitive advantage in sustainability
"The CompMate system exceeded our expectations. Not only did we achieve significant cost savings, but the IoT monitoring gives us complete visibility into our energy consumption patterns. This has become a model for our other manufacturing facilities."
Rajesh Kumar
Plant Engineering Manager, Leading Auto Manufacturer
Key Success Factors
Technical Excellence
- • Proper system sizing and design
- • Strategic placement for maximum heat capture
- • Integration with existing infrastructure
- • IoT monitoring for continuous optimization
Project Management
- • Comprehensive pre-installation assessment
- • Minimal production disruption during installation
- • Thorough testing and commissioning
- • Ongoing support and maintenance
Ready to Achieve Similar Results?
Discover how CompMate can reduce your facility's energy costs while supporting sustainability goals