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Energy conservation depends more on the compressed air system

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Kuntan Panchal, Joint Managing Director of Indo Air Compressors.

Indo Air Compressors manufactures reciprocating air and water cooled compressors. It has a very modern factory, spanning across an area of 6300 sq m. The company has been continually adopting best engineering practices to lift the product quality to new heights. Young and dynamic Kuntan Panchal, Joint Managing Director of Indo Air Compressors, has pushed the turnover growth of Indo Air by 25 per cent in just three years of his association with the firm. He has also been instrumental in orienting the company to develop advanced compressors to meet the market demands. The company has harnessed its state- of- the- art R&D facility to develop highly energy efficient systems. Here he talks about what to look for in compressors and how to get the best out of them. Excerpts from the interview.

Tell us about the range of compressors offered by your company.

We manufacture both piston type reciprocating compressors and rotary screw compressors. The piston type reciprocating compressors includes single-stage for low pressure application, two-stage models for medium pressure application and the high pressure models of multi stage models. The connected load of the compressors range from 1 HP to 30 HP. The state-of-the-art rotary screw compressor manufactured by us emits very little noise, making it ideally suitable for installation within the factory area. Our screw compressors range from 7.5 HP to 100 HP now and plans are afoot to manufacture up to 300 HP systems.

Reciprocating type compressors in the oil-free version from 0.5 HP to 15 HP are also available for the industry where completely oil-free air is required. This has special application in hospitals.

Other products from Indo Air include vacuum pumps from 2 HP to 10 HP and heavy-duty water cooled vertical compressor from 25 to 60 HP.

The latest addition to our range is the high pressure water- cooled, oil-free IAH series compressor, from 40 HP to 150 HP models.

Which are your latest breakthrough products?

To ensure the product quality in the production of PET bottles, containers for home care/cosmetic products, food products, pharmaceutical products, aeronautics, turbine and hydraulic circuit pressurising and pharmaceutical industries, Indo Air has developed its new IAH hundred per cent oil-free high pressure series compressors.

Catering to the need of hospital for clean oil-free air systems has been a focus of Indo Air for many years. Indo Air’s NL type compressors were well received in the market. Indo Air Vacuum pumps have satisfied the demands of hospitals to the fullest.

How can one rationalise the use of compressed air and improve the efficiency of compressor?

There are various steps that could be taken to improve the efficiency of compressors and can help in using compressed air effectively.

  • Use of high efficient and higher pull-out torque electrical motors has been found to give power savings in different plants; power savings of around 5 to 8 per cent was recorded at many plants.
  • Variable Speed Drives (VSD) for the compressors improves the power consumption pattern of the compressors. Of course, this depends on the usage and air output linked to the air pressure requirements. The savings VSDs provide vary between 10 to 40 per cent depending on the flow pattern.
  • Proper sizing of the pipe diameter contributes significantly to lower the power consumption; increasing the pipe diameter typically reduces annual energy consumption by 3-4 per cent.
  • When the compressor works, it produces heat and it is simple physics that compressing air gives off heat. The heat energy gets stored in the decreasing volume of air. To maintain proper operating temperatures, the compressor must transfer excess heat to a cooling media before the air goes out into the pipe system. As much as 90 per cent of that heat can be recovered for use in your operation. If you can supplement or replace the electricity, gas or oil needed to create hot water for washrooms or direct warm air into a workspace, warehouse or for any other use, the savings can add up significantly. The possibilities to recover this waste heat via hot air or hot water are very good. The return on the investment for energy recovery is usually as short as one to three years. In addition, energy recovered by means of a closed loop cooling system (for water cooled compressors) is advantageous to the compressor’s operating conditions, reliability and service life.
  • If the input temperature to the compressor is reduced by placing the compressor inlet strategically, the energy consumption of the compressor can be reduced to the extent of 1-2 per cent for every 3-4 degree drop in inlet temperature.
  • Often, the air-cooled compressors are relegated to boiler rooms that do not have proper ventilation. These centralised compressors can experience elevated operating temperatures that reduce equipment life, increase maintenance and repair cost, and ultimately can yield an unreliable air system. The initial cost of a good ventilation system is usually far less than the ongoing increased maintenance costs of a hot operating environment.
  • System operators should also examine if a reduced system pressure could be used. Use of a central control system can run the existing air compressors to cyclical demand more effectively.
  • Increased storage capacity can also reduce the unnecessary high cycling demand of compressors.

Which features in your equipment help in the energy conservation?

With regard to the rationalisation of the use of compressed air, energy conservation depends more on the compressed air system than the elements built into the compressor. However, there are a few which are already available or can be built into Indo Air compressors.

Indo Air has been incorporating innovative ideas in the design of its reciprocating compressors. One such instance is to change the cylinder diameter combination, resulting in reduced speed of the compressor leading to drop in temperature built up. The Automatic Start-Stop control can be modified to have a solenoid valve system to have a pressure free start up of the compressor thus reducing the starting current demand of the electric motor. The water-cooled, inter-cooler can be provided as an option to reduce the input temperature of air at the subsequent stages. Variable speed drives is offered with the screw compressors to reduce energy consumption.

What kind of testing and quality checks does your equipment go through?

All internal assemblies are carried out in a dust-free closed assembly room to protect the internal moving parts. This room is adequately furbished to have the necessary tools, test benches, air lines and inspection facilities. The quality plan for the assembly is displayed at every stage of the compressor assembly to ensure a repetitive set performance of the compressors. All critical parts are inspected one hundred per cent for dimensional as well as geometrical accuracy. All castings and raw material purchases are accompanied by chemical and physical property reports. All compressors leaving the premises of Indo Air are tested for its performance, efficiency and the quality. Every model of the compressor is tested once in two months on a test bed established specially for this purpose, with calibrated instruments and measurement devices, where the nozzle is tested at various parameters as specified in the relevant Indian Standard and sometimes, rechecks are carried out.

There is a monitoring system in place on the compressor at the customer’s place and the feedback is used to update the check list in the assembly. For every deviation noticed, a Quality Assurance Report (QAR) is prepared with the action taken to eliminate the error. We are a certified ISO 9000-2008 company and all quality practices are followed from design, procurement, inspection, assembly and testing, and proper records are maintained.

What are the new developments in compressor operations, design and maintenance processes?

With the advent of microprocessor systems, modern air compressors are now available with user friendly software systems to operate, control and maintain the equipment. All Indo Air screw compressors and high pressure, water-cooled reciprocating compressors come with a Indo-numeric PLC based control system software to control the compressor. Its user-friendly touchscreen MMI allows the operator to modify the parameters.

The system monitors, regulates, does error diagnosis and gives out warning signals, both visual and audible, preventing potential damages to the equipment. It also gives service warning signals to indicate oil filter/air filter change and such other service requirements.

The provision of an auto shutdown ensures shutting down of the compressors in case of abnormal parameters, to avert system damage. In the high pressure, water-cooled compressor control, there is a port available in the controller for a computer connection. Using this facility, remote sensing of the compressor can be performed via the internet for troubleshooting, from the Indo Air factory.

Double-acting cylinders have been incorporated into the new design, instead of single acting cylinders; this gives two compressor strokes for every revolution of the crank, thus doubling the output. Now booster compressors are developed where high output and high pressure of air is required. These designs use the advantage of both reciprocating and rotary screw compressors, compressors with a smaller footprint.

How have you incorporated safety into your design?

The air compressor is fitted with several safety components.

The first is an unloading valve. The unloading valve allows the air to escape from the compression chamber when there is a strain on the electrical motor.

The pressure inside the air receiver must never exceed the manufacturer’s recommendations. If the pressure is greater than the recommended level, it may cause an explosion. The pressure in the air receiver is controlled by the pressure switch. To adjust the pressure, simply turn the switch in the desired direction.

Pressure relief valves are also installed on the compressor system. These valves allow air to escape from the system when the pressure goes beyond the desired level. The valves operate automatically.

The air intake valve is fitted with an air filter. The filter prevents dust from being drawn into the compression cylinder. If dust enters the compressor, the heat inside the cylinder can cause the dust to catch fire. Fire inside the cylinder may cause damage to the air compressor. For this reason, it is important to make sure that the air filter is clean and securely connected to the compressor.

Moisture too, can cause problems and so another filter must be installed to take out the moisture out of the compressed air. The moisture is usually removed using a filter and moisture separator assembly which is installed between the air compressor and the air receiver. It removes the moisture and dust from the compressed air before it enters the air receiver.

An automatic control device is attached to the air receiver. It controls the starting and stopping of the air compressor. It shuts down the compressor when the air pressure in the air receiver is adequate. It restarts the air compressor when there is a need for more pressure.

A cooling system is installed in each air compression unit. The compression chamber and the compressed air must be cooled. Small compressors are usually air-cooled. The air is circulated around the compressor by a fan. Large air compressors are usually water-cooled. Cold water is pumped throughout the compressor. Both the air and water cooling systems prevent the compressors from overheating and causing serious damage. The air compressor is also fitted with a low oil level indicator switch. This indicator switch automatically shuts down the air compressor if the oil level is low. The compressor should not be operated if the oil is low as this can cause serious damage to the compressor. Do not attempt to run the air compressor until the oil is replaced.

These measures are a must for the safety of the equipment and also for the people working in the factory. We at Indo Air take additional precautions with all compressor parts under air pressure. All the air receivers, inter-coolers and after -coolers, pressure pipes, are tested hydraulically at 2.5 times the designed pressure.

Selecting The Right Compressor

An air compressor is a valuable piece of equipment for operating power equipment or tools. The type you need depends on the equipments you will be using.

  • Consider how often you will use an air compressor and how it will be used. What tools will you be using and how much power will be needed to operate them? Some tools like nail guns use low volume of compressed air whereas other equipment, such as drills or sanders needs high volumes because they require a steady air flow.
  • Consider the power of the compressor; consider both the horsepower and pound per square inch (PSI) pressure. Make sure it is more powerful than the most powerful equipment you will be using.
  • The type of the compressor depends on the volume of air required and the air pressure. Normally in a cement plant, the compressor is located in a room far away from the equipment to be operated. There will be a significant pressure drop and this should be taken in to account while selecting the compressor.
  • With the availability of screw compressors with high volume outputs, with a closed canopy, it is possible to install these types of compressors in the shop floor itself, close to the equipment, resulting in minimum pressure loss.
  • The tank size is another important factor. The more you use the equipment, the larger the tank you will need. Always go a little larger than you think you will need, this will ensure that you can get the optimum use from the compressor and reduced power consumption.
  • List out the accessories you may need with the compressor and include them in the buying order.

Concrete

India donates 225t of cement for Myanmar earthquake relief

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On 23 May 2025, the Indian Navy ship UMS Myitkyina arrived at Thilawa (MITT) port carrying 225 tonnes of cement provided by the Indian government to aid post-earthquake rebuilding efforts in Myanmar. As reported by the Global Light of Myanmar, a formal handover of 4500 50kg cement bags took place that afternoon. The Yangon Region authorities managed the loading of the cement onto trucks for distribution to the earthquake-affected zones.

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Concrete

Reclamation of Used Oil for a Greener Future

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In this insightful article, KB Mathur, Founder and Director, Global Technical Services, explores how reclaiming used lubricants through advanced filtration and on-site testing can drive cost savings, enhance productivity, and support a greener industrial future. Read on to discover how oil regeneration is revolutionising sustainability in cement and core industries.

The core principle of the circular economy is to redefine the life cycle of materials and products. Unlike traditional linear models where waste from industrial production is dumped/discarded into the environment causing immense harm to the environment;the circular model seeks to keep materials literally in continuous circulation. This is achievedthrough processes cycle of reduction, regeneration, validating (testing) and reuse. Product once
validated as fit, this model ensures that products and materials are reintroduced into the production system, minimising waste. The result? Cleaner and greener manufacturing that fosters a more sustainable planet for future generations.

The current landscape of lubricants
Modern lubricants, typically derived from refined hydrocarbons, made from highly refined petroleum base stocks from crude oil. These play a critical role in maintaining the performance of machinery by reducing friction, enabling smooth operation, preventing damage and wear. However, most of these lubricants; derived from finite petroleum resources pose an environmental challenge once used and disposed of. As industries become increasingly conscious of their environmental impact, the paramount importance or focus is shifting towards reducing the carbon footprint and maximising the lifespan of lubricants; not just for environmental reasons but also to optimise operational costs.
During operations, lubricants often lose their efficacy and performance due to contamination and depletion of additives. When these oils reach their rejection limits (as they will now offer poor or bad lubrication) determined through laboratory testing, they are typically discarded contributing to environmental contamination and pollution.
But here lies an opportunity: Used lubricants can be regenerated and recharged, restoring them to their original performance level. This not only mitigates environmental pollution but also supports a circular economy by reducing waste and conserving resources.

Circular economy in lubricants
In the world of industrial machinery, lubricating oils while essential; are often misunderstood in terms of their life cycle. When oils are used in machinery, they don’t simply ‘DIE’. Instead, they become contaminated with moisture (water) and solid contaminants like dust, dirt, and wear debris. These contaminants degrade the oil’s effectiveness but do not render it completely unusable. Used lubricants can be regenerated via advanced filtration processes/systems and recharged with the use of performance enhancing additives hence restoring them. These oils are brought back to ‘As-New’ levels. This new fresher lubricating oil is formulated to carry out its specific job providing heightened lubrication and reliable performance of the assets with a view of improved machine condition. Hence, contributing to not just cost savings but leading to magnified productivity, and diminished environmental stress.

Save oil, save environment
At Global Technical Services (GTS), we specialise in the regeneration of hydraulic oils and gear oils used in plant operations. While we don’t recommend the regeneration of engine oils due to the complexity of contaminants and additives, our process ensures the continued utility of oils in other applications, offering both cost-saving and environmental benefits.

Regeneration process
Our regeneration plant employs state-of-the-art advanced contamination removal systems including fine and depth filters designed to remove dirt, wear particles, sludge, varnish, and water. Once contaminants are removed, the oil undergoes comprehensive testing to assess its physico-chemical properties and contamination levels. The test results indicate the status of the regenerated oil as compared to the fresh oil.
Depending upon the status the oil is further supplemented with high performance additives to bring it back to the desired specifications, under the guidance of an experienced lubrication technologist.
Contamination Removal ? Testing ? Additive Addition
(to be determined after testing in oil test laboratory)

The steps involved in this process are as follows:
1. Contamination removal: Using advanced filtration techniques to remove contaminants.
2. Testing: Assessing the oil’s properties to determine if it meets the required performance standards.
3. Additive addition: Based on testing results, performance-enhancing additives are added to restore the oil’s original characteristics.

On-site oil testing laboratories
The used oil from the machine passes through 5th generation fine filtration to be reclaimed as ‘New Oil’ and fit to use as per stringent industry standards.
To effectively implement circular economy principles in oil reclamation from used oil, establishing an on-site oil testing laboratory is crucial at any large plants or sites. Scientific testing methods ensure that regenerated oil meets the specifications required for optimal machine performance, making it suitable for reuse as ‘New Oil’ (within specified tolerances). Hence, it can be reused safely by reintroducing it in the machines.
The key parameters to be tested for regenerated hydraulic, gear and transmission oils (except Engine oils) include both physical and chemical characteristics of the lubricant:

  • Kinematic Viscosity
  • Flash Point
  • Total Acid Number
  • Moisture / Water Content
  • Oil Cleanliness
  • Elemental Analysis (Particulates, Additives and Contaminants)
  • Insoluble

The presence of an on-site laboratory is essential for making quick decisions; ensuring that test reports are available within 36 to 48 hours and this prevents potential mechanical issues/ failures from arising due to poor lubrication. This symbiotic and cyclic process helps not only reduce waste and conserve oil, but also contributes in achieving cost savings and playing a big role in green economy.

Conclusion
The future of industrial operations depends on sustainability, and reclaiming used lubricating oils plays a critical role in this transformation. Through 5th Generation Filtration processes, lubricants can be regenerated and restored to their original levels, contributing to both environmental preservation and economic efficiency.
What would happen if we didn’t recycle our lubricants? Let’s review the quadruple impacts as mentioned below:
1. Oil Conservation and Environmental Impact: Used lubricating oils after usage are normally burnt or sold to a vendor which can be misused leading to pollution. Regenerating oils rather than discarding prevents unnecessary waste and reduces the environmental footprint of the industry. It helps save invaluable resources, aligning with the principles of sustainability and the circular economy. All lubricating oils (except engine oils) can be regenerated and brought to the level of ‘As New Oils’.
2. Cost Reduction Impact: By extending the life of lubricants, industries can significantly cut down on operating costs associated with frequent oil changes, leading to considerable savings over time. Lubricating oils are expensive and saving of lubricants by the process of regeneration will overall be a game changer and highly economical to the core industries.
3. Timely Decisions Impact: Having an oil testing laboratory at site is of prime importance for getting test reports within 36 to 48 hours enabling quick decisions in critical matters that may
lead to complete shutdown of the invaluable asset/equipment.
4. Green Economy Impact: Oil Regeneration is a fundamental part of the green economy. Supporting industries in their efforts to reduce waste, conserve resources, and minimise pollution is ‘The Need of Our Times’.

About the author:
KB Mathur, Founder & Director, Global Technical Services, is a seasoned mechanical engineer with 56 years of experience in India’s oil industry and industrial reliability. He pioneered ‘Total Lubrication Management’ and has been serving the mining and cement sectors since 1999.

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Concrete

Charting the Green Path

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The Indian cement industry has reached a critical juncture in its sustainability journey. In a landmark move, the Ministry of Environment, Forest and Climate Change has, for the first time, announced greenhouse gas (GHG) emission intensity reduction targets for 282 entities, including 186 cement plants, under the Carbon Credit Trading Scheme, 2023. These targets, to be enforced starting FY2025-26, are aligned with India’s overarching ambition of achieving net zero emissions by 2070.
Cement manufacturing is intrinsically carbon-intensive, contributing to around 7 per cent of global GHG emissions, or approximately 3.8 billion tonnes annually. In India, the sector is responsible for 6 per cent of total emissions, underscoring its critical role in national climate mitigation strategies. This regulatory push, though long overdue, marks a significant shift towards accountability and structured decarbonisation.
However, the path to a greener cement sector is fraught with challenges—economic viability, regulatory ambiguity, and technical limitations continue to hinder the widespread adoption of sustainable alternatives. A major gap lies in the lack of a clear, India-specific definition for ‘green cement’, which is essential to establish standards and drive industry-wide transformation.
Despite these hurdles, the industry holds immense potential to emerge as a climate champion. Studies estimate that through targeted decarbonisation strategies—ranging from clinker substitution and alternative fuels to carbon capture and innovative product development—the sector could reduce emissions by 400 to 500 million metric tonnes by 2030.
Collaborations between key stakeholders and industry-wide awareness initiatives (such as Earth Day) are already fostering momentum. The responsibility now lies with producers, regulators and technology providers to fast-track innovation and investment.
The time to act is now. A sustainable cement industry is not only possible—it is imperative.

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