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Speaking numbers from a Kenyan cable manufacturer
One of the biggest challenges in optimizing compressed air usage is knowing exactly where, how, and when to take action. By using the VPFlowScope In-line flow meter for real-time measurement, our customer in Kenya gained valuable insights into their compressed air system. This allowed them to identify clear opportunities for energy savings, calculate the Return on Investment (ROI), and make informed, data-driven decisions. This case shows how a flow meter is a powerful tool to turn data into action.
The challenge in the cable manufacturing industry
Our customer, an electrical and communication cable manufacturer in Kenya, produces cables for both domestic and international industrial applications. In cable manufacturing, the drying phase (removing all water after cooling) is essential to ensure product quality.
Previously, the customer used two hollow cylindrical pipes to direct compressed air onto the cables for drying. However, this unmonitored system led to multiple issues, including inconsistent drying, excessive compressed air consumption, high noise levels, and hidden energy losses. Without proper measurement, it was impossible to determine the efficiency or actual cost of the process.
With VPFlowScope In-line, our customer was able to easily calculate the Return On Investment and make rational decisions.
To optimize the drying phase and reduce compressed air-related energy losses, the customer tested a new air wipe system. They used the VPFlowScope In-line 0.5” flow meter to measure and compare compressed air usage in both the old and new systems, bringing much-needed visibility to what had previously been an unmonitored and inefficient part of production.
Monitoring utilities with a flow meter
Compressed air monitoring during the experiment provided valuable insights into the performance of the old and new systems:
Before – The old facilitated system
The two facilitated hollow cylindrical pipes had 4 and 20 diameter holes respectively. Each hole is 4 mm in diameter and consumes 3 SCFM of air at 5.5 bar:
1st pipe: 3 SCFM x 4 holes = 12 SCFM
2nd pipe: 3 SCFM x 20 holes = 60 SCFM
Annual energy cost:
72 SCFM x ( 22 kW / 100 SCFM ) x 2,000 hrs x 0.13 Euro / kWhr = € 4,118
After – The new air wipe
The new air wipe with 3” internal diameter replaced both pipes, while using 55% less compressed air at 5.5 bar.
New air wipe consumes: 39.8 SCFM
Annual energy cost:
39.8 SCFM x ( 22 kW / 100 SCFM ) x 2,000 hrs x 0.13 Euro / kWhr = € 2,278
Annual savings: € 4,118 – € 2,278 = € 1,840
Main withdrawals
> Total energy saving per machine: € 1,840
> Investment cost: € 691
> Payback period: 4.4 months
Thanks to accurate compressed air monitoring with the VPFlowScope In-line flow meter, the customer could clearly compare energy consumption, calculate ROI, and confidently switch to the new system.
Conclusions
> With the VPFlowScope In-line, the customer was able to easily calculate the ROI and make rational decisions.
> Thanks to the new air wipe system the customer could save 45% energy cost per production machine, all the cables are completely dry without using sponges afterward.
> Permanent flow meters can enable customers to fully monitor any changes in air demand and act immediately to prevent loss.
