Plastics Manufacturer Cuts Compressor Energy Use by 34% with ALUP EVOLUTO in 10th of Ramadan
Case study: How a leading plastics injection plant in 10th of Ramadan reduced compressor power consumption by 34% and cut its scrap rate with an ALUP EVOLUTO 75 kW compressor.
Illustrative example: this study shows typical results for similar projects and does not describe a named customer. Actual savings depend on each plant.
Operational Strain & Inefficient Air Delivery
The facility operates 14 plastic injection molding machines running 24 hours a day. Their previous fixed-speed 90 kW compressor could not adapt to fluctuating pneumatic demand as molds opened and closed at varying cycles. The system spent over 42% of its operating hours in "unloaded" (idle) state—consuming nearly 35 kW of electricity without delivering useful air. Furthermore, severe pressure drops from 8.0 bar down to 5.8 bar occurred during simultaneous mold cycles, resulting in incomplete part fillings, surface defects, and a 4.8% scrap rate.
Custom System Architecture & ALUP Deployment
Flowva Air's engineering team conducted a comprehensive 7-day data-logged air audit, logging flow rates, pressure variations, and power draw every second. We engineered a complete station upgrade centered around the **ALUP EVOLUTO 75 kW** with integrated Permanent Magnet (iPM) motor and smart inverter speed modulation. The station was complemented by an **ALUP ADQ 900 Refrigerant Dryer** (+3°C pressure dew point) and an oversized 2,000-liter air receiver to absorb instantaneous demand surges.
Cost Reductions & Long-Term Reliability
Within the first 3 months of commissioning, electrical sub-meter data confirmed a 34% drop in specific power consumption. Line pressure now remains firmly pinned at 7.5 bar (±0.1 bar tolerance) regardless of how many injection machines cycle simultaneously. Plastic part scrap dropped from 4.8% to under 0.4%.
ALUP EVOLUTO 75 kW (iPM VSD) + ADQ 900 Dryer + 2000L Receiver
Engineered German air-end paired with permanent magnet VSD motor and tropical heat exchangers.
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