Honda Motors Manufacturing
Automotive Plant, Chennai - CompMate Success Story
The Challenge
Honda Motors' Chennai manufacturing facility faced escalating energy costs for hot water generation across multiple applications:
- Paint Booth Operations: Required consistent hot water supply for cleaning and maintenance processes
- Employee Facilities: Canteen and washroom hot water systems running 24/7
- Process Heating: Various manufacturing processes requiring heated water
- Cost Impact: Annual electricity bill of ₹18 lakhs solely for hot water heating
The plant management was seeking sustainable solutions to reduce operating costs while meeting their corporate sustainability commitments for carbon neutrality by 2050.
The Solution
System Design: Promethean Energy installed 3 CompMate units on Honda's 75kW air compressors, strategically positioned to capture maximum waste heat.
Technical Specifications
- 3x CompMate units (25kW each)
- Heat recovery efficiency: 65%
- Hot water output: 55-75°C
- Flow rate: 2,500 L/hour total
- Double-walled safety system
IoT Monitoring Features
- Real-time performance dashboard
- Energy savings tracking
- Predictive maintenance alerts
- Mobile app remote monitoring
- Automated reporting
Installation Process: The installation was completed over a planned 3-day shutdown period with minimal disruption to production operations. Our team worked closely with Honda's engineering staff to ensure seamless integration.
Results & Impact
Financial Benefits
- 42% reduction in hot water heating costs
- ₹7.5 lakhs annual energy savings
- 16-month payback period
- 15-year system lifespan with minimal maintenance
Environmental Impact
- 85 tonnes CO2 reduction annually
- 125 MWh energy saved per year
- Contributes to Honda's carbon neutrality goals
- Green energy certification achieved
Operational Excellence
"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. The system has been incredibly reliable, and we're now planning to implement this solution at our other manufacturing facilities across India."
Project Timeline
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