Water Conservation Technology Yields 4.3M Gallon Reduction and Energy Efficiencies
Xpress® technology enabled a Fortune 500 manufacturer to expand production while satisfying company-wide sustainability mandates.
773,200
annual kWh savings
4,300,000
gallons of water saved annually
location
India
size
5,000 tons capacity
industry
Building Materials
the problem
Balancing Growth with Corporate Sustainability Mandates
A Mumbai-based fiberglass manufacturing plant faced multiple challenges simultaneously. A corporate mandate required reducing manufacturing energy intensity across all facilities. At the same time, growing demand necessitated the replacement of an antiquated chilled water plant with a new 5,000-ton system. The company needed an energy-efficient design service and optimization solution that could address both requirements without compromising production, while significantly improving upon the water and energy performance of the outdated system.
the solution
Expert Hydronic Design & Customized Technology Implementation
tekWorx was selected for this critical project based on their proven hydronic expertise, mechanical engineering capabilities, and track record of successful implementations across similar industrial environments. tekWorx engineers implemented a comprehensive approach to maximize efficiency in the new cooling system:
- Designed and implemented a Variable Primary hydronic system that adjusts water flow based on real-time cooling demands
- Installed Xpress® technology on Allen-Bradley ControlLogix PLCs to ensure maximum system efficiency while maintaining necessary cooling requirements at the lowest total kW/ton
- Created a customized Energy Efficiency Performance Dashboard that provides real-time monitoring of system performance, including kW and kW/ton metrics for each major equipment piece and the entire chilled water system
tekWorx hydronic expertise was refreshingly practical and their collaborative approach made the entire process seamless.
Mechanical Design Engineering Leader
the results
Water, Energy, and Bottom Line
The implementation of Xpress® technology delivered multiple benefits that highlight how saving water directly translates to saving energy:
- Annual energy costs reduced by $117,000 compared to pre-construction estimates
- 4.3 million gallons of water saved annually compared to projected consumption of the conventional design approach, representing a dramatic improvement over the previous antiquated system
- Improved facility operations through lower costs, more reliable water supply, and better water quality
- 3-year project payback period
By implementing innovative cooling technology, the Mumbai site successfully addressed business growth, regulatory compliance, and sustainability goals while securing substantial financial benefits. While every plant has its inherent inefficiencies, this success demonstrates that significant efficiency improvement and utility savings are always possible with the right partner.