Embroidery
Embroidery
Case Study: Reducing Energy Costs and Eliminating Downtime in an Embroidery Unit
Improving Efficiency and Reliability Across a Multi-Floor Embroidery Facility
A high-efficiency UPS solution that reduced electricity costs by 35% while ensuring uninterrupted operations.
Client Snapshot
- Industry: Textile / Embroidery
- Facility: Multi-floor Embroidery Unit
- Deployment: 3 Floors
- UPS Installed: o 30kVA (3-Phase to 1-Phase) × 2
o 20kVA (3-Phase to 1-Phase) × 1 - Backup Time: 4 Hours
The Challenge
A large embroidery unit operating across three different floors was facing persistent operational and cost-related issues with their existing UPS infrastructure.
The client was already using UPS systems from multiple brands, but encountered:
- Frequent breakdowns, leading to interruptions in production
- High dependency on service support and increased downtime
- Lack of reliability across different floors
In addition to reliability concerns, the client noticed that electricity bills were unusually high, not aligning with the actual machine load.
Upon conducting a detailed power audit, it was discovered that:
- The existing UPS systems were highly inefficient
- Significant energy was being lost due to outdated and inefficient technology
- The UPS systems themselves were contributing heavily to excess power consumption
The client required a solution that could:
- Provide reliable, uninterrupted power across all floors
- Reduce energy consumption and operational costs
- Replace multiple ineƯicient systems with a more dependable setup
Solution Provided
We deployed Enventa make DSP-Based Online UPS systems across all three floors, tailored to the load requirements of each level.
Installed Configuration:
- 30kVA (3:1) UPS × 2
- 20kVA (3:1) UPS × 1
- 4-hour backup for continuous production support
Key Features of the Solution:
- High-efficiency DSP-based technology
- Faster response and improved reliability compared to conventional systems
- Optimized energy consumption for long operational hours
- Consistent and stable power supply across all floors
Why This Solution Was Effective
- DSP-based UPS systems significantly reduced energy losses, improving overall efficiency
- Eliminated frequent breakdowns, ensuring continuous production flow
- Provided stable and reliable power for sensitive embroidery machines
- Optimized performance across multiple floors with customized capacity planning
Key Highlights
- Multi-floor deployment with tailored UPS capacities
- Replacement of multiple unreliable systems with a unified solution
- Significant improvement in energy eƯiciency
- Enhanced operational reliability
Results
- 35% reduction in electricity costs attributed to UPS systems
- Complete elimination of frequent breakdown issues
- Improved production continuity and reduced downtime
- Lower maintenance and service dependency
- Stable and eƯicient power infrastructure across all floors
Conclusion
By replacing ineƯicient legacy systems with high-eƯiciency DSP-based UPS solutions, the client achieved a significant reduction in energy costs while enhancing operational reliability. The solution delivered both immediate savings and long-term performance benefits for a multi-floor industrial setup.