CoolingSolutions
Issue 03 Oct-Dec 2014
A.T.E. PRIVATE LIMITEDE: [email protected] W: www.ateindia.com, www.ategroup.com
Inside
Foreword 2
In Focus 2 HMX – a business unit of A.T.E.
Clean Talk Interview of Mr R Srinivasan, Head of Projects,
Himalaya Drug Company 4
Product Showcase
® Valence Valflow Ink Temperature Stabiliser (ITS) 6
TechUpdate EcoAxis’ remote monitoring for chillers 6
EcoTouch 8
Foreword
Dear Readers
Welcome back to the latest edition of GreenLink! I hope you are all set for a great 2015. I hope you'll have a happy and healthy year!
This issue of our newsletter centres largely on air, in one way or the other. A growing body of evidence points to the criticality of g o o d q u a l i t y a i r i n
maintaining health and in enhancing productivity. For example, a recent study (The Light and Heat: Productivity Co-benefits of Energy Saving Technology, February 24, 2014) points to the clear correlation between air temperature and the productivity on 29 garment factories in and around Bengaluru. Various studies at health care facilities around the world suggest that higher fresh air volumes per person significantly reduce infection rates. From both of these examples, we see that investing in better air quality has benefits. The capex and opex optimised energy saving technology of HMX, which is explained in some detail in the following sections, shows how these benefits can be translated into quick payback.
In the gravure printing process, as solvent is a major process intermediary, the best solvent is the solvent you never use! Valence's ITS range helps you do just this — minimise fugitive losses significantly — thus saving money and improving air quality. The resulting payback is startlingly fast – just 6 months on solvent saving alone! As air pollution control norms tighten, the Valence ITS will further prove its worth as it will lower both the capacity required for VOC treatment and operational costs. A brief case study presented in this issue based on early customer experience with the ITS, makes a strong pitch for resource use efficiency in the paper, film, and foil converting industry. Added to this, are our regular features: • An interview (with Mr R Srinivasan, Head of
Projects, Himalaya Drug Company) • A technical write-up (on remote monitoring of
chillers)
I hope this edition of GreenLink will give you plenty of ideas in ways by which you can improve your bottom line through cleverer, environment friendly ways.
With best wishes,Anuj Bhagwati
Anuj Bhagwati, Director - A.T.E. group
2
In Focus
HMX – a business unit of A.T.E.
A breath of fresh air can work wonders. A growing number of studies in the education, healthcare, and manufacturing industries have shown an increase in productivity with higher fresh air content. In a peer-reviewed study in 2003, operators at a call centre in a tropical climate zone performed nearly 9% better when fresh air levels were increased. Offices and dormitories with higher fresh air content have reported lower incidences of flu and respiratory tract infection.
If fresh air can work wonders, fresh cooled a i r could be even better. That precisely is what HMX, a business unit of A.T.E., does, w i t h i t s u n i q u e , patented technology. It provides fresh cooled air for the industrial and commercial sectors that not only ensures people comfort and thereby enhances productivity, but also improves process efficiency, all that in an environment friendly way without the heavy power use of air conditioners, at an affordable lifecycle cost!
Today more and more large corporates and multinationals from across segments such as automobiles, engineering, food and beverage, etc., are turning to HMX for innovative cooling solutions to increase the satisfaction of their workforce, and also for storage and process areas where treated fresh air is a must. The resulting demand for HMX's eco-friendly cooling solutions has resulted in a rapidly increasing installation base that has already crossed 20 million CFM in India.
HMX, which was earlier HMX Systems Private Limited, has been in the business of providing eco-friendly cooling solutions since 1999 and operates out of Bengaluru, India. It designs and manufactures unique,
HMX-Ambiator installation
3
energy-efficient, and eco-friendly products for space and process cooling. It also undertakes turnkey projects for comfort air conditioning with its products as core. HMX's manufacturing facility in Peenya Industrial Area, Bengaluru, employs more than 50 skilled people and is certified under ISO 9001:2008 for its quality practices. Adopting some of the best manufacturing practices and stringent quality checks, HMX rolls out products that are best of class.
At the heart of all HMX products is the DAMA (Dry Air Moist Air) – a patented heat exchanger (we have received US and Australian patents). It's a cross flow plate type sensible heat exchanger built out of an engineering polymer, which p rov ides a non -co r ros i ve , non -biodegradable, and anti-bacterial substrate, and has an efficiency of more than 80%. Supply air on one side is cooled by a secondary stream of air that flows in alternating moist channels. The vaporizing mass of water in the secondary stream enables cooling of the supply air without any water addition to the cooled air. DAMA is sturdily constructed to ensure trouble-free performance for several years. Also, HMX's core products do not rely on harmful refrigerants and energy intensive compressors to supply cool air.
HMX's projects use different configurations to supply fresh, clean, and cool air: • Only Indirect Evaporative Cooling (IEC) • Combination of Indirect and Direct Evaporative
Cooling (IDEC) • Combination of indirect evaporative cooling and
cooling coils (DX or chilled water)
The first of the innovative products that HMX has introduced is the HMX-Ambiator. The HMX-Ambiator is a two stage evaporative cooling solution, which is an excellent upgrade over air washers and normal ventilation systems, as well as an energy efficient alternative to conventional air conditioners. The two stages of cooling i.e., “indirect evaporative cooling”
HMX-PCU-F installation at TeraSpin
(sensible cooling – no moisture addition), followed by “direct evaporative cooling” (adiabatic cooling), enables the HMX-Ambiator to deliver air cooled below the concurrent atmospheric wet bulb temperature. Available in various capacities starting from 10,000 CFM, the HMX-Ambiator comes with an integrated control panel with PLC controller and several other options such as variable speed drives, remote monitoring, etc. It can be used for cooling large spaces in various industries or commercial buildings for process requirements and/or to
maintain a comfortable environment for the staff.
The success of the HMX-Ambiator is now followed by the recent launch of two more innovative pre-cooling fresh air units, the HMX-PCU-F and HMX-PCU-R. The HMX-PCU-F is an innovative technology product that supplies
filtered, conditioned, and fresh air in designated areas. This system has 'Indirect Evaporative Cooling (IEC)' at the first stage for sensible cooling and then an optional AC coil (DX/CW) at the second stage. Incorporating IEC at the first stage can result in substantial energy savings. It can be used as standalone solution in conjunction with AHUs/large chiller installations, with or without the AC coil. It yields energy savings while introducing fresh air in commercial buildings to improve IAQ (Indoor Air Quality). It can also be used as a pre-cooler. It finds application across various sectors such as hospitals, auditoriums, malls, multiplexes, commercial complexes, gyms, offices, sport complexes, exhibition halls, pubs, lounges, etc.
The HMX-PCU-R is a next generation heat (energy) recovery unit. Conventional AC systems typically require 10-15% of fresh air. While inducting this fresh air, some conditioned air needs to be exhausted. The HMX-PCU-R helps in recovering the energy from this outgoing air and pre-cools the fresh air. This acts as an energy recovery device and in turn lowers the TR load on the air conditioning system. Since there is no silica gel type rotating wheel, there is no wear and tear, no deterioration of efficiency over time, and no cross contamination, and no heating is required to re-generate silica gel. Again, it can be used at hotels, hospitals, auditoriums, malls, multiplexes, commercial complexes, gyms, offices, sport complexes, exhibition halls, pubs, lounges, factories, etc., where cooled fresh air is needed and return air is available.
Having established itself as an expert in energy efficient 'cooling solutions', HMX has received accolades at various platforms. This includes winning the 'ISHRAE
At the heart of all HMX products is the DAMA (Dry Air Moist Air) – a patented cross flow plate type sensible heat exchanger, built out of an engineering polymer.
HMX-PCU-R
Foreword
Dear Readers
Welcome back to the latest edition of GreenLink! I hope you are all set for a great 2015. I hope you'll have a happy and healthy year!
This issue of our newsletter centres largely on air, in one way or the other. A growing body of evidence points to the criticality of g o o d q u a l i t y a i r i n
maintaining health and in enhancing productivity. For example, a recent study (The Light and Heat: Productivity Co-benefits of Energy Saving Technology, February 24, 2014) points to the clear correlation between air temperature and the productivity on 29 garment factories in and around Bengaluru. Various studies at health care facilities around the world suggest that higher fresh air volumes per person significantly reduce infection rates. From both of these examples, we see that investing in better air quality has benefits. The capex and opex optimised energy saving technology of HMX, which is explained in some detail in the following sections, shows how these benefits can be translated into quick payback.
In the gravure printing process, as solvent is a major process intermediary, the best solvent is the solvent you never use! Valence's ITS range helps you do just this — minimise fugitive losses significantly — thus saving money and improving air quality. The resulting payback is startlingly fast – just 6 months on solvent saving alone! As air pollution control norms tighten, the Valence ITS will further prove its worth as it will lower both the capacity required for VOC treatment and operational costs. A brief case study presented in this issue based on early customer experience with the ITS, makes a strong pitch for resource use efficiency in the paper, film, and foil converting industry. Added to this, are our regular features: • An interview (with Mr R Srinivasan, Head of
Projects, Himalaya Drug Company) • A technical write-up (on remote monitoring of
chillers)
I hope this edition of GreenLink will give you plenty of ideas in ways by which you can improve your bottom line through cleverer, environment friendly ways.
With best wishes,Anuj Bhagwati
Anuj Bhagwati, Director - A.T.E. group
2
In Focus
HMX – a business unit of A.T.E.
A breath of fresh air can work wonders. A growing number of studies in the education, healthcare, and manufacturing industries have shown an increase in productivity with higher fresh air content. In a peer-reviewed study in 2003, operators at a call centre in a tropical climate zone performed nearly 9% better when fresh air levels were increased. Offices and dormitories with higher fresh air content have reported lower incidences of flu and respiratory tract infection.
If fresh air can work wonders, fresh cooled a i r could be even better. That precisely is what HMX, a business unit of A.T.E., does, w i t h i t s u n i q u e , patented technology. It provides fresh cooled air for the industrial and commercial sectors that not only ensures people comfort and thereby enhances productivity, but also improves process efficiency, all that in an environment friendly way without the heavy power use of air conditioners, at an affordable lifecycle cost!
Today more and more large corporates and multinationals from across segments such as automobiles, engineering, food and beverage, etc., are turning to HMX for innovative cooling solutions to increase the satisfaction of their workforce, and also for storage and process areas where treated fresh air is a must. The resulting demand for HMX's eco-friendly cooling solutions has resulted in a rapidly increasing installation base that has already crossed 20 million CFM in India.
HMX, which was earlier HMX Systems Private Limited, has been in the business of providing eco-friendly cooling solutions since 1999 and operates out of Bengaluru, India. It designs and manufactures unique,
HMX-Ambiator installation
3
energy-efficient, and eco-friendly products for space and process cooling. It also undertakes turnkey projects for comfort air conditioning with its products as core. HMX's manufacturing facility in Peenya Industrial Area, Bengaluru, employs more than 50 skilled people and is certified under ISO 9001:2008 for its quality practices. Adopting some of the best manufacturing practices and stringent quality checks, HMX rolls out products that are best of class.
At the heart of all HMX products is the DAMA (Dry Air Moist Air) – a patented heat exchanger (we have received US and Australian patents). It's a cross flow plate type sensible heat exchanger built out of an engineering polymer, which p rov ides a non -co r ros i ve , non -biodegradable, and anti-bacterial substrate, and has an efficiency of more than 80%. Supply air on one side is cooled by a secondary stream of air that flows in alternating moist channels. The vaporizing mass of water in the secondary stream enables cooling of the supply air without any water addition to the cooled air. DAMA is sturdily constructed to ensure trouble-free performance for several years. Also, HMX's core products do not rely on harmful refrigerants and energy intensive compressors to supply cool air.
HMX's projects use different configurations to supply fresh, clean, and cool air: • Only Indirect Evaporative Cooling (IEC) • Combination of Indirect and Direct Evaporative
Cooling (IDEC) • Combination of indirect evaporative cooling and
cooling coils (DX or chilled water)
The first of the innovative products that HMX has introduced is the HMX-Ambiator. The HMX-Ambiator is a two stage evaporative cooling solution, which is an excellent upgrade over air washers and normal ventilation systems, as well as an energy efficient alternative to conventional air conditioners. The two stages of cooling i.e., “indirect evaporative cooling”
HMX-PCU-F installation at TeraSpin
(sensible cooling – no moisture addition), followed by “direct evaporative cooling” (adiabatic cooling), enables the HMX-Ambiator to deliver air cooled below the concurrent atmospheric wet bulb temperature. Available in various capacities starting from 10,000 CFM, the HMX-Ambiator comes with an integrated control panel with PLC controller and several other options such as variable speed drives, remote monitoring, etc. It can be used for cooling large spaces in various industries or commercial buildings for process requirements and/or to
maintain a comfortable environment for the staff.
The success of the HMX-Ambiator is now followed by the recent launch of two more innovative pre-cooling fresh air units, the HMX-PCU-F and HMX-PCU-R. The HMX-PCU-F is an innovative technology product that supplies
filtered, conditioned, and fresh air in designated areas. This system has 'Indirect Evaporative Cooling (IEC)' at the first stage for sensible cooling and then an optional AC coil (DX/CW) at the second stage. Incorporating IEC at the first stage can result in substantial energy savings. It can be used as standalone solution in conjunction with AHUs/large chiller installations, with or without the AC coil. It yields energy savings while introducing fresh air in commercial buildings to improve IAQ (Indoor Air Quality). It can also be used as a pre-cooler. It finds application across various sectors such as hospitals, auditoriums, malls, multiplexes, commercial complexes, gyms, offices, sport complexes, exhibition halls, pubs, lounges, etc.
The HMX-PCU-R is a next generation heat (energy) recovery unit. Conventional AC systems typically require 10-15% of fresh air. While inducting this fresh air, some conditioned air needs to be exhausted. The HMX-PCU-R helps in recovering the energy from this outgoing air and pre-cools the fresh air. This acts as an energy recovery device and in turn lowers the TR load on the air conditioning system. Since there is no silica gel type rotating wheel, there is no wear and tear, no deterioration of efficiency over time, and no cross contamination, and no heating is required to re-generate silica gel. Again, it can be used at hotels, hospitals, auditoriums, malls, multiplexes, commercial complexes, gyms, offices, sport complexes, exhibition halls, pubs, lounges, factories, etc., where cooled fresh air is needed and return air is available.
Having established itself as an expert in energy efficient 'cooling solutions', HMX has received accolades at various platforms. This includes winning the 'ISHRAE
At the heart of all HMX products is the DAMA (Dry Air Moist Air) – a patented cross flow plate type sensible heat exchanger, built out of an engineering polymer.
HMX-PCU-R
4
Awards of Excellence' for three consecutive years 2010-12 in different categories, recognition by TERI, and nomination for the “World Clean Energy Awards” under the products category at New York in May 2007.
Committed to develop the technology further, HMX has set-up a test laboratory in Peenya. The test lab is equipped with facilities for accurate generation of conditioned air with desired parameters of temperature and humidity and, testing of DAMA heat exchangers with different secondary air, wet bulb temperature combinat ions, to determine heat exchanger performance at different conditions, etc.
HMX's fast expanding customer base includes many of the who's who of the corporate world. Some of its customers include ABB, Alkem, Amanora, Bilcare, Bosch, Coca Cola, Caterpillar, Dabur, DB Group, Forbes Marshall, GE, HAL, Himalaya, Honeywell, ICC Devi Gaurav, ICRISAT, ITC, KTTM, Lupin, NRB, Pluss Polymer, Relaxo, SKF, Suzlon, Syntel, Tata Motors, TeraSpin, TVS, Victor Reinz, VW, Infosys, TCPL, MBR flexibles, Apex Packaging, Jindal Polyfilms, Flipkart, MRF etc. Many customers have placed repeat orders with HMX. What attracts and brings customers back to HMX is not just the unique technology, product quality and performance that are indeed a class apart, but HMX's focus on customer service. HMX has a dedicated service set-up imbued with passion for customer service, and has set itself a high standard for customer service.
Today, HMX works seamlessly with all units of the A.T.E. group, ensuring a country-wide sales, service, and project management network. With its domain expertise and relentless efforts at customer satisfaction, HMX is looking to grow fast.
Clean Talk
Interview of Mr R Srinivasan, Head of Projects, Himalaya Drug Company
Himalaya Drug Company, a renowned healthcare brand in India, has recently i n s t a l l e d t w o H M X -Ambiators in its Bengaluru plant. In an exclusive i n te r v i ew w i t h A .T.E . G r e e n L i n k , M r R S r i n i v a s a n , H e a d o f Projects, Himalaya Drug Company, talks about the company, performance of HMX-Ambiators, and his experience working with HMX.
15,000 CFM HMX-Ambiator installed at Himalaya's Bengaluru plant
A.T.E.: The Himalaya Drug Company has been a leading medicinal company for several years now. Can you please brief us about the company, its product range, and the market it caters to?
Mr Srinivasan: The Himalaya Drug Company was established by Mr M Manal in the year 1930 in Bengaluru. We cater to the ayurvedic pharmaceutical market. We have a wide range of products which includes pharmaceuticals, personal care products, baby care products, nutritional products and animal care products, marketed under the Himalaya Wellness brand.
A.T.E.: Could you please explain to us the problems you faced in the storage area?
Mr Srinivasan: The storage area and the production block area at Himalaya's state-of-the-art factory, are
2spread over 25,000 ft . Herbal raw material in the form of granules/powder and liquid are stored here before being taken into production. As per International Regulatory Authorities (IRA), raw material should be stored only at temperatures below 30 °C. During the summer season the temperature inside the storage area could soar to 38 °C as it was only ventilated. This was not acceptable.
A.T.E.: What were the different cooling solutions that you evaluated for this requirement? How did you arrive at the conclusion that two stage cooling was ideally suited for this application?
Mr Srinivasan: We had evaluated the feasibility of either installing a refrigerant based air conditioning system or a single stage evaporative air cooling system, to meet our requirement.
Air conditioning was ruled out because of high operational and maintenance costs. We also ruled out the option of using a single stage evaporative cooling as this technology would not be able to maintain temperatures below 30 °C throughout the year.
That was when we zeroed on to two stage evaporative
R Srinivasan, Head of Projects, Himalaya Drug Company
5
cooling as an ideal solution as it would help us to maintain temperatures as per our requirement at a much lower operational and maintenance costs. Thus, as per the recommendations of HMX's sales team, we installed two HMX-Ambiators of 15,000 CFM each for the storage area.
A.T.E.: We are sure your decision to go in for the HMX-Ambiator must have been taken after detailed evaluation of other options available in the market. Could you please tell us what were the deciding factors in favor of the HMX-Ambiator?
Mr Srinivasan: We already have installed the HMX-Ambiator for our dining area a few years ago and we are happy with its performance. So, it has been relatively easy for us to decide in favour of the HMX-Ambiator because of our satisfactory experience.
Also, the application engineering based information that we got from the HMX team made our job further easy during the evaluation process. The detailed technical inputs given by the HMX team convinced us beyond doubt that this was the ideal solution for us.
A.T.E.: It is now more than a year since you have installed the HMX-Ambiator. Has it met the requirements initially thought of before the projects? Could you please compare the benefits of using the HMX-Ambiator especially in your raw material section to your expectations?
Mr Srinivasan: It has definitely met the requirements initially thought of before the project. The primary requirement was maintaining temperatures below 30 °C on a regular basis and we are happy to state that since the commissioning of the HMX-Ambiators, the temperature inside the storage area has never crossed 28 °C. In a way this performance has exceeded our expectations.
As a result of this, we no more have to worry a b o u t t h e temperature rising b e y o n d t h e I R A standards.
A.T.E.: Could you please share with us your views on the product overall, in
terms of technology, features, and aesthetics and your suggestions for improvement?
Mr Srinivasan: This technology is a time tested technology and we do not have an iota of doubt about the efficacy of the HMX-Ambiator. We have seen the product constantly evolve in terms of features and aesthetics
over the years, since we first installed it at our dining area.
New features like the UV filtration system for internal water filtration, canopy on top of the machine to protect it from rain water, PLC to monitor the operating sequence of the machine and to identify the trip indication of pumps, motor, sensors etc., for easy maintenance are worth mentioning.
We have full faith in team HMX and are sure that they will continue their endeavor of constantly improving the product.
A.T.E.: We will be happy if you could share with us your experience dealing with HMX in this project, from pre-sales to installation to post-sales support and also your suggestion for improvement.
Mr Srinivasan: Team HMX handled this project very professionally all the way from the pre-sales period to the post-sales period.
To start with all our queries were answered satisfactorily during the technical evaluation process by means of calculations and charts. After the order was placed, the projects team skillfully used the existing ducting system, as per our request, to put the system in place.
Their professional approach also ensured that regular day to day operations inside the area were not hampered.
Timely execution of the project was of essence and team HMX diligently ensured that the entire project was executed on time.
A.T.E.: Are you planning to go for more installations of the HMX-Ambiator at Himalaya and if so tentatively by when and for which section?
Mr Srinivasan: We would definitely like to go for more installations of the HMX-Ambiator in the future, but we do not have any immediate plans as of now.
A . T. E . : W i l l y o u recommend the HMX-Ambiator to others, and if so why?
Mr Srinivasan: We w i l l c e r t a i n l y recommend the HMX-Ambiator to others in our industry as we are glad to be using a highly efficient product. We believe we have set a standard in the pharmaceutical industry, which also adds value to our overall image in the market.
We will certainly recommend the HMX-Ambiator to others in our industry as we are glad to be using a highly efficient product.
4
Awards of Excellence' for three consecutive years 2010-12 in different categories, recognition by TERI, and nomination for the “World Clean Energy Awards” under the products category at New York in May 2007.
Committed to develop the technology further, HMX has set-up a test laboratory in Peenya. The test lab is equipped with facilities for accurate generation of conditioned air with desired parameters of temperature and humidity and, testing of DAMA heat exchangers with different secondary air, wet bulb temperature combinat ions, to determine heat exchanger performance at different conditions, etc.
HMX's fast expanding customer base includes many of the who's who of the corporate world. Some of its customers include ABB, Alkem, Amanora, Bilcare, Bosch, Coca Cola, Caterpillar, Dabur, DB Group, Forbes Marshall, GE, HAL, Himalaya, Honeywell, ICC Devi Gaurav, ICRISAT, ITC, KTTM, Lupin, NRB, Pluss Polymer, Relaxo, SKF, Suzlon, Syntel, Tata Motors, TeraSpin, TVS, Victor Reinz, VW, Infosys, TCPL, MBR flexibles, Apex Packaging, Jindal Polyfilms, Flipkart, MRF etc. Many customers have placed repeat orders with HMX. What attracts and brings customers back to HMX is not just the unique technology, product quality and performance that are indeed a class apart, but HMX's focus on customer service. HMX has a dedicated service set-up imbued with passion for customer service, and has set itself a high standard for customer service.
Today, HMX works seamlessly with all units of the A.T.E. group, ensuring a country-wide sales, service, and project management network. With its domain expertise and relentless efforts at customer satisfaction, HMX is looking to grow fast.
Clean Talk
Interview of Mr R Srinivasan, Head of Projects, Himalaya Drug Company
Himalaya Drug Company, a renowned healthcare brand in India, has recently i n s t a l l e d t w o H M X -Ambiators in its Bengaluru plant. In an exclusive i n te r v i ew w i t h A .T.E . G r e e n L i n k , M r R S r i n i v a s a n , H e a d o f Projects, Himalaya Drug Company, talks about the company, performance of HMX-Ambiators, and his experience working with HMX.
15,000 CFM HMX-Ambiator installed at Himalaya's Bengaluru plant
A.T.E.: The Himalaya Drug Company has been a leading medicinal company for several years now. Can you please brief us about the company, its product range, and the market it caters to?
Mr Srinivasan: The Himalaya Drug Company was established by Mr M Manal in the year 1930 in Bengaluru. We cater to the ayurvedic pharmaceutical market. We have a wide range of products which includes pharmaceuticals, personal care products, baby care products, nutritional products and animal care products, marketed under the Himalaya Wellness brand.
A.T.E.: Could you please explain to us the problems you faced in the storage area?
Mr Srinivasan: The storage area and the production block area at Himalaya's state-of-the-art factory, are
2spread over 25,000 ft . Herbal raw material in the form of granules/powder and liquid are stored here before being taken into production. As per International Regulatory Authorities (IRA), raw material should be stored only at temperatures below 30 °C. During the summer season the temperature inside the storage area could soar to 38 °C as it was only ventilated. This was not acceptable.
A.T.E.: What were the different cooling solutions that you evaluated for this requirement? How did you arrive at the conclusion that two stage cooling was ideally suited for this application?
Mr Srinivasan: We had evaluated the feasibility of either installing a refrigerant based air conditioning system or a single stage evaporative air cooling system, to meet our requirement.
Air conditioning was ruled out because of high operational and maintenance costs. We also ruled out the option of using a single stage evaporative cooling as this technology would not be able to maintain temperatures below 30 °C throughout the year.
That was when we zeroed on to two stage evaporative
R Srinivasan, Head of Projects, Himalaya Drug Company
5
cooling as an ideal solution as it would help us to maintain temperatures as per our requirement at a much lower operational and maintenance costs. Thus, as per the recommendations of HMX's sales team, we installed two HMX-Ambiators of 15,000 CFM each for the storage area.
A.T.E.: We are sure your decision to go in for the HMX-Ambiator must have been taken after detailed evaluation of other options available in the market. Could you please tell us what were the deciding factors in favor of the HMX-Ambiator?
Mr Srinivasan: We already have installed the HMX-Ambiator for our dining area a few years ago and we are happy with its performance. So, it has been relatively easy for us to decide in favour of the HMX-Ambiator because of our satisfactory experience.
Also, the application engineering based information that we got from the HMX team made our job further easy during the evaluation process. The detailed technical inputs given by the HMX team convinced us beyond doubt that this was the ideal solution for us.
A.T.E.: It is now more than a year since you have installed the HMX-Ambiator. Has it met the requirements initially thought of before the projects? Could you please compare the benefits of using the HMX-Ambiator especially in your raw material section to your expectations?
Mr Srinivasan: It has definitely met the requirements initially thought of before the project. The primary requirement was maintaining temperatures below 30 °C on a regular basis and we are happy to state that since the commissioning of the HMX-Ambiators, the temperature inside the storage area has never crossed 28 °C. In a way this performance has exceeded our expectations.
As a result of this, we no more have to worry a b o u t t h e temperature rising b e y o n d t h e I R A standards.
A.T.E.: Could you please share with us your views on the product overall, in
terms of technology, features, and aesthetics and your suggestions for improvement?
Mr Srinivasan: This technology is a time tested technology and we do not have an iota of doubt about the efficacy of the HMX-Ambiator. We have seen the product constantly evolve in terms of features and aesthetics
over the years, since we first installed it at our dining area.
New features like the UV filtration system for internal water filtration, canopy on top of the machine to protect it from rain water, PLC to monitor the operating sequence of the machine and to identify the trip indication of pumps, motor, sensors etc., for easy maintenance are worth mentioning.
We have full faith in team HMX and are sure that they will continue their endeavor of constantly improving the product.
A.T.E.: We will be happy if you could share with us your experience dealing with HMX in this project, from pre-sales to installation to post-sales support and also your suggestion for improvement.
Mr Srinivasan: Team HMX handled this project very professionally all the way from the pre-sales period to the post-sales period.
To start with all our queries were answered satisfactorily during the technical evaluation process by means of calculations and charts. After the order was placed, the projects team skillfully used the existing ducting system, as per our request, to put the system in place.
Their professional approach also ensured that regular day to day operations inside the area were not hampered.
Timely execution of the project was of essence and team HMX diligently ensured that the entire project was executed on time.
A.T.E.: Are you planning to go for more installations of the HMX-Ambiator at Himalaya and if so tentatively by when and for which section?
Mr Srinivasan: We would definitely like to go for more installations of the HMX-Ambiator in the future, but we do not have any immediate plans as of now.
A . T. E . : W i l l y o u recommend the HMX-Ambiator to others, and if so why?
Mr Srinivasan: We w i l l c e r t a i n l y recommend the HMX-Ambiator to others in our industry as we are glad to be using a highly efficient product. We believe we have set a standard in the pharmaceutical industry, which also adds value to our overall image in the market.
We will certainly recommend the HMX-Ambiator to others in our industry as we are glad to be using a highly efficient product.
Product Showcase
6
®Valflow Ink Temperature Stabiliser (ITS) provides big savings in solvent consumption through ink cooling on rotogravure and flexographic printing presses
Recent studies have shown that warm ink is a major dampener to pressroom economics. It lowers print quality by destroying the dot structure and it causes increased use of inks and solvents. Valence Electrons Private Limited, an A.T.E. group company, has developed the
®Valflow Ink Temperature Stabiliser (ITS) – that significantly reduces inks and solvents consumption and also helps improve print quality.
Here is a case study
Background
A leading Mumbai based converter, manufacturing flexible packaging laminates, uses an 8 colour CI flexographic printing press for both surface and reverse printing on 1350 mm wide films that run at a maximum speed of 300 m/min. Solvent based inks, having a viscosity of 20 seconds (B4 cup) were used. The customer sought to reduce ink and solvent consumption, and thereby improve operating margins.
Challenge
On each print station, an ink circulating pump delivers ink from the tank to the chamber. As the print run progresses, temperature of the ink rose, and subsequently stabilised at a high temperature over time. Higher ink temperatures means higher solvent evaporation, which results in higher top-up solvent consumption.
Solution
The Valence technical team made an in-depth study of the process, and deduced that a heat exchanger was needed to reduce ink temperature to a level that reduces solvent consumed, without hindering the process. Critical design parameters considered were ambient conditions, temperature and flow rate of the ink, permissible pressure drop of the application and quantity of heat to be transferred through the heat exchanger. The team evaluated the application data through heat exchange and CFD modeling to arrive at a compact design with optimal performance. The heat exchanger had to be dependable (leak proof) with water as the
®media of heat transfer. The Valflow ITS has a low pressure drop and is sleek, simple to retrofit, easy to
clean, and highly affordable.
Result
Without a heat exchanger, temperature of the ink stabilised at 32 °C when product iv i ty was at an o p t i m u m l e v e l . O n
®introducing the Valflow ITS, ink temperature during operation reduced to 28 °C. Lowering ink temperature by 4 °C saw a reduction in top-up solvent consumption by 33%, while maintaining the same printing performance. The resultant annualized savings, after installation of
®Valflow ITS on all eight print stations, with associated accessories, water chilling plant, etc. translated into a payback period of less than 6 months!
TechUpdate
Manage your chillers using cloud technology
Introduction
Chillers, using either vapour compression or vapour absorption technology, are widely used in industry for process cooling of exothermic processes and also in facilities for de-humidification and comfort cooling.
Chillers are, however, fraught with operational challenges of maintenance and efficiency management in order to keep the availability high and the total cost of ownership under control. Many a time, silent losses cause energy and maintenance costs to spiral out of control before they are realized. Though frequent examination of critical parameters and related expert analysis can help identifying such losses, remote and multiple locations of chillers in multi-plant scenarios and the distributed nature of the installed base of OEMs pose logistic challenges to plant owners and OEM service experts for such exercises.
A real-time continuous and centralised information system that tracks and analyses critical parameters and provides analytics for users to take corrective action, goes a long way in not only realising overall cost savings but also
Sample alerts
ITS
Viscosity controller
7
Chiller performance at a glance with alerts & acts
improving workforce efficiency, productivity, and safety.
EcoAxis remote monitoring technology
EcoAxis' IoT (Internet of Things) based remote monitoring solution with big data analytics has been deployed by many OEMs and plant owners. This solution is used to monitor various operating parameters of chillers on a real time basis and allows users to access and analyse information anytime, anywhere through their PCs and mobile devices. As a result, it not only helps accelerating decision making by remote experts by assisting in problem avoidance, maintenance and repairs, but also allows local workers take corrective measures transforming them to problem solving experts.
How remote monitoring works
Our remote monitoring system – SUPERAxis™ – consists of hardware & software connectors that log data from machines, instruments, and sensors at defined regular intervals. Using cloud-based computing, it delivers analytics and alerts in the form of reports, dash boards, emails and SMS – any device, anytime, anywhere.
Solution Architecture:
Key benefits for OEMs:
• Managing assets – any device, any time, any where • Extend asset usable lifecycle, reliability, and
availability
• Reduce MTTR (Mean Time To Repair) and increase MTBF (Mean Time Between Failures)
• Service delivery optimisation • Customer warranty and SLA compliance • Higher customer retention • Identify cross-selling and up-selling opportunities • Specific analytics related to chiller performance built
in by process experts • Performance benchmarking
Key benefits to end users:
• Continuous monitoring of production, productivity, availability and loses in real time
• Identify and address deviations quickly • Continuous measurement and verification for energy
efficiency • Real-time reporting of KPIs to keep track of
operational effectiveness and performance • Role based analytical dashboards and alerts for
quick decision support • Track and manage MTTR and MTBF • Track equipment health – instill predictive/condition-
based maintenance • Benchmarking across all plants
With far reaching benefits, EcoAxis' IoT (Internet of Things) based remote monitoring solution is the way forward for optimising the performance and resource consumption of chillers both for OEMs and end users.
Solution architecture
Runtime summary report
Maintenance summary report
Product Showcase
6
®Valflow Ink Temperature Stabiliser (ITS) provides big savings in solvent consumption through ink cooling on rotogravure and flexographic printing presses
Recent studies have shown that warm ink is a major dampener to pressroom economics. It lowers print quality by destroying the dot structure and it causes increased use of inks and solvents. Valence Electrons Private Limited, an A.T.E. group company, has developed the
®Valflow Ink Temperature Stabiliser (ITS) – that significantly reduces inks and solvents consumption and also helps improve print quality.
Here is a case study
Background
A leading Mumbai based converter, manufacturing flexible packaging laminates, uses an 8 colour CI flexographic printing press for both surface and reverse printing on 1350 mm wide films that run at a maximum speed of 300 m/min. Solvent based inks, having a viscosity of 20 seconds (B4 cup) were used. The customer sought to reduce ink and solvent consumption, and thereby improve operating margins.
Challenge
On each print station, an ink circulating pump delivers ink from the tank to the chamber. As the print run progresses, temperature of the ink rose, and subsequently stabilised at a high temperature over time. Higher ink temperatures means higher solvent evaporation, which results in higher top-up solvent consumption.
Solution
The Valence technical team made an in-depth study of the process, and deduced that a heat exchanger was needed to reduce ink temperature to a level that reduces solvent consumed, without hindering the process. Critical design parameters considered were ambient conditions, temperature and flow rate of the ink, permissible pressure drop of the application and quantity of heat to be transferred through the heat exchanger. The team evaluated the application data through heat exchange and CFD modeling to arrive at a compact design with optimal performance. The heat exchanger had to be dependable (leak proof) with water as the
®media of heat transfer. The Valflow ITS has a low pressure drop and is sleek, simple to retrofit, easy to
clean, and highly affordable.
Result
Without a heat exchanger, temperature of the ink stabilised at 32 °C when product iv i ty was at an o p t i m u m l e v e l . O n
®introducing the Valflow ITS, ink temperature during operation reduced to 28 °C. Lowering ink temperature by 4 °C saw a reduction in top-up solvent consumption by 33%, while maintaining the same printing performance. The resultant annualized savings, after installation of
®Valflow ITS on all eight print stations, with associated accessories, water chilling plant, etc. translated into a payback period of less than 6 months!
TechUpdate
Manage your chillers using cloud technology
Introduction
Chillers, using either vapour compression or vapour absorption technology, are widely used in industry for process cooling of exothermic processes and also in facilities for de-humidification and comfort cooling.
Chillers are, however, fraught with operational challenges of maintenance and efficiency management in order to keep the availability high and the total cost of ownership under control. Many a time, silent losses cause energy and maintenance costs to spiral out of control before they are realized. Though frequent examination of critical parameters and related expert analysis can help identifying such losses, remote and multiple locations of chillers in multi-plant scenarios and the distributed nature of the installed base of OEMs pose logistic challenges to plant owners and OEM service experts for such exercises.
A real-time continuous and centralised information system that tracks and analyses critical parameters and provides analytics for users to take corrective action, goes a long way in not only realising overall cost savings but also
Sample alerts
ITS
Viscosity controller
7
Chiller performance at a glance with alerts & acts
improving workforce efficiency, productivity, and safety.
EcoAxis remote monitoring technology
EcoAxis' IoT (Internet of Things) based remote monitoring solution with big data analytics has been deployed by many OEMs and plant owners. This solution is used to monitor various operating parameters of chillers on a real time basis and allows users to access and analyse information anytime, anywhere through their PCs and mobile devices. As a result, it not only helps accelerating decision making by remote experts by assisting in problem avoidance, maintenance and repairs, but also allows local workers take corrective measures transforming them to problem solving experts.
How remote monitoring works
Our remote monitoring system – SUPERAxis™ – consists of hardware & software connectors that log data from machines, instruments, and sensors at defined regular intervals. Using cloud-based computing, it delivers analytics and alerts in the form of reports, dash boards, emails and SMS – any device, anytime, anywhere.
Solution Architecture:
Key benefits for OEMs:
• Managing assets – any device, any time, any where • Extend asset usable lifecycle, reliability, and
availability
• Reduce MTTR (Mean Time To Repair) and increase MTBF (Mean Time Between Failures)
• Service delivery optimisation • Customer warranty and SLA compliance • Higher customer retention • Identify cross-selling and up-selling opportunities • Specific analytics related to chiller performance built
in by process experts • Performance benchmarking
Key benefits to end users:
• Continuous monitoring of production, productivity, availability and loses in real time
• Identify and address deviations quickly • Continuous measurement and verification for energy
efficiency • Real-time reporting of KPIs to keep track of
operational effectiveness and performance • Role based analytical dashboards and alerts for
quick decision support • Track and manage MTTR and MTBF • Track equipment health – instill predictive/condition-
based maintenance • Benchmarking across all plants
With far reaching benefits, EcoAxis' IoT (Internet of Things) based remote monitoring solution is the way forward for optimising the performance and resource consumption of chillers both for OEMs and end users.
Solution architecture
Runtime summary report
Maintenance summary report
EcoTouch
8
on 26-28 Feb 2015
at BIEC, Bengaluru
Visit us at Cooling Solutions
Hall 3A
Stall 573-574
EcoAxis – a best end-to-end solution provider
EcoAxis was awarded for being the best end-to-end solution provider at the Automation & Robotics Show 2014 held on September 19-21, 2014 in Pune. This show, which is a popular trade fair for the automation industry, gave EcoAxis a good opportunity to promote its unique M2M solutions for industrial plants. Remote monitoring being a new concept, the stall was abuzz with keen and potential customers.
EcoAxis participates in Sugar Expo
EcoAxis participated in the 73rd annual Convention & Sugar Expo held at Bengaluru on September 9-11, 2014. This event gave EcoAxis a good platform to showcase its state-of-the-art solution for managing the data from shop floor to top floor exclusively for the sugar industry. The expo was a huge success for EcoAxis as the customers showed keen interest in M2M remote monitoring solution, which is quite a new and innovative concept, especially for the sugar industry.
EcoAxis at M2M Conclave India 2014
EcoAxis participated as conference partner at the M2M Conclave India on September 19, 2014, in Mumbai. In India, M2M market has now started evolving – Indian M2M market will be majorly driven by automotive & commercial telematics, household monitoring & control, financial services & retail, smart homes & smart meter ing, manufactur ing, transportation and logistics. Mr Abhay Nalawade – CEO, EcoAxis, shared his ideas regarding M2M communication, Internet of Things, and its need for industry. EcoAxis, which is as an established end-to-end solution provider in the M2M segment received an overwhelming response.
