Impact of LPG on Core Drying Oven

Switching to LPG from High Speed Diesel

A case study of a customer who slashed high fuel costs and achieved cleaner workplace by choosing SR-Grade LPG

Abstract

This case study highlights a leading multinational manufacturer of commercial vehicle engine parts that previously relied on Diesel for their core drying oven application. Driven by rising fuel charges and the inefficiencies of manually ordering fuel in bulk, they decided to explore alternatives like LPG and partnered with SUPERGAS. This shift, marked a significant breakthrough towards operational cost and environmental responsibility.

Role of LPG in Core Drying Oven

Core drying oven play a crucial role in the manufacturing, where it is used to remove moisture from sand cores used in metal casting processes. These ovens must operate efficiently at high temperatures to ensure the thorough drying of cores.

LPG provides a more consistent and controllable thermal output compared to HSD, which ensures uniform drying of cores and avoiding casting defects like blowholes or sand fusion. The efficient burning of LPG reduces the relative humidity inside the drying oven, yielding better integrity and strength in the finished products.

Benefits of Partnering with SUPERGAS

Our partnership thrived as we transitioned a customer from HSD to LPG for their core drying oven needs. SUPERGAS maximized existing premises by repurposing a scrap yard shed for the LPG yard, optimizing space utilization. Despite initial hesitations due to high energy demands and 24/7 operations, we allayed their concerns with a comprehensive cost-benefit analysis, guaranteeing ROI within a year.

Our offer of 8X450Kg Maxima Plus installations ensured uninterrupted supply, convincing the customer of our capability to meet their production energy needs effectively.

Operational Impact Study

While Using HSD	After Switching to LPG
High fuel usage results in on-site storage, posing a health risk.	Uninterrupted LPG supply with very few nos. of cylinders to handle.
This is no automated process to support order management and billing processes.	IVRS system, independent of manual intervention.
High operational and maintenance cost	Approximately Rs.20,00,000/- per annum cost saved by conversion.
Downtime required for cleaning/maintenance of the oven and risk of spillage.	No downtime for cleaning/maintenance of the oven and no spillage.
The smoke generated by HSD fuel had an impact on employee’s health.	The smoke-free environment inside the plant avoided eye irritation for their employees.