Textile Mill in Borg El Arab Cuts Air System Energy by 28% via Ultrasonic Leak Audit & VSD
Case study: How an export textile mill in Borg El Arab cut its compressed air energy use by 28% through Flowva Air ultrasonic leak audits and an ALUP EVOLUTO 90 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
Operating 120 air-jet weaving looms that consume massive volumes of air at constant 7.0 bar, the compressed air station was one of the mill's largest electricity consumers. The aging piping network suffered from undocumented air leaks, while older compressors struggled in Alexandria's humid summer heat, frequently tripping on thermal alarms and leaving expensive yarn broken on the looms.
Custom System Architecture & ALUP Deployment
Flowva Air dispatched its diagnostic engineering team with ultrasonic leak detectors, surveying over 1,400 meters of overhead compressed air piping. We mapped, tagged, and fixed 38 significant pipe and fitting leaks that were wasting 1.4 m³/min of compressed air. To replace the inefficient old machines, we installed an **ALUP EVOLUTO 90 kW** variable-speed compressor with an oversized tropical cooling pack alongside dual **ALUP ADQ 1080 dryers**.
Cost Reductions & Long-Term Reliability
The combined impact of ultrasonic leak remediation and the EVOLUTO's iPM motor slashed the plant's compressed air power draw by 28%. Air-jet looms now receive rock-solid pressure, yarn breaks fell by 40%, and zero summer heat shutdowns occurred.
ALUP EVOLUTO 90 kW iPM + Dual ADQ 1080 Dryers + Ultrasonic Leak Remediation
Engineered German air-end paired with permanent magnet VSD motor and tropical heat exchangers.
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