Iconic Casting, a pivotal customer of DISA India located in Kolhapur, has been utilizing various DISA solutions like the MATCH 24/28 moulding line, DISA Mixer, and Wheelabrator shot blast machine since 2011. Their operations involved the use of the DISA TM240 intensive Mixer with Fluid Coupling Drive. While effective, the Fluid Coupling required regular attention during operations, limiting the mixer load to 80% of its batch capacity.
"We're delighted with the transformative results brought by DISA India's innovative approach. The shift from the Fluid Coupling to the Soft Starter not only optimized our electricity usage but also significantly reduced breakdowns.
This step toward sustainability aligns with our environmental concerns, making us proud of our association with DISA India. We look forward to further collaboration to optimize our other equipment."
– K S Patil, Manager Maintenance, Iconic casting
Background:
Iconic Casting, a pivotal customer of DISA India located in Kolhapur, has been utilizing various DISA solutions like the MATCH 24/28 moulding line, DISA Mixer, and Wheelabrator shot blast machine since 2011. Their operations involved the use of the DISA TM240 intensive Mixer with Fluid Coupling Drive. While effective, the Fluid Coupling required regular attention during operations, limiting the mixer load to 80% of its batch capacity.
Challenges and Solutions Offered:
Iconic Casting expressed the desire for enhanced productivity and minimized breakdowns in their DISA Mixer. DISA India's Aftermarket team, recognizing the need for increased output and reduced downtime, proposed a power-saving solution to optimize the Mixer's productivity. To address this, DISA India's Aftermarket team replaced the Fluid Coupling with a Soft Starter, a sustainable energy solution tailored for the foundry industry.
Results Achieved:
The implementation of the Soft Starter yielded remarkable results for Iconic Casting. With a 10% reduction in energy consumption per batch (measured in KWH), Iconic achieved a substantial annual savings of 0.3 million INR. Additionally, the frequency of breakdowns reduced significantly, and the mixer operation became virtually maintenance-free. Notably, the load capacity of the mixer also witnessed improvement.
Conclusion:
The collaboration between DISA India's Aftermarket team and Iconic Casting exemplifies a successful integration of sustainable energy solutions into foundry operations. The adoption of the Soft Starter not only addressed operational challenges but also delivered substantial savings and a reduction in environmental impact. This success story stands as a testament to the effectiveness of innovative aftermarket solutions in enhancing productivity and promoting sustainability within the foundry industry.
DISA India Limited, Region: IMEA