Increasing energy efficiency and helping to reduce operational and maintenance costs for Manjushree Technopack through enhanced equipment performance
Indian Plastics Industry – not just thriving but growing rapidly India has a thriving and extremely competitive plastics industry. It is set to buck the global trend of sluggish growth by emerging as one of the fastest growing markets with 2020, the plastics consumption of the country expected to increase from about 12 million metric tonnes per annum (MMTPA) as in 2016 to 20 MMTPA by 2020. By that time India is expected to deploy about 180,000 machines as compared to 113,000 in 2016. In the past, the use of plastics in India was largely limited to household consumer durables and packaging. Now, plastics are also widely used in infrastructure, health care as well as in agriculture. The consumer market for automobiles and electronic goods - both major users of plastics - is also growing rapidly which would add to the growth of the industry.
Indian Plastics Industry – not just thriving but growing rapidly
India has a thriving and extremely competitive plastics industry. It is set to buck the global trend of sluggish growth by emerging as one of the fastest growing markets with 2020, the plastics consumption of the country expected to increase from about 12 million metric tonnes per annum (MMTPA) as in 2016 to 20 MMTPA by 2020. By that time India is expected to deploy about 180,000 machines as compared to 113,000 in 2016. In the past, the use of plastics in India was largely limited to household consumer durables and packaging. Now, plastics are also widely used in infrastructure, health care as well as in agriculture. The consumer market for automobiles and electronic goods – both major users of plastics – is also growing rapidly which would add to the growth of the industry.
Productivity is a crucial determinant in performance which in turn defines the progress or growth of any company. This naturally puts focus on maximising productivity while reducing unscheduled downtime and costs. Within the majority of plastic injection moulding applications, hydraulic oils play a fundamental role in the actual production of plastic components as well as helping to reduce unscheduled downtime and extend oil drain intervals. Hence while accounting for a relatively small percentage of total maintenance spends, the latest hydraulic oils have the potential to inject additional productivity and performance into plastic manufacturing operations. Advancements in hydraulic oil technology now offer plastics manufacturers a selection of fluids that can help produce high quality components and provide outstanding levels of protection, as well as other benefits such as increased energy efficiency and decreased cycle times.
Background/ Situation at hand
Established in 1983, Manjushree Technopack Ltd. is a leading rigid plastics packaging convertor in India and South Asia. It has its largest capacity in the segments of blow moulding containers and PET preforms. Manjushree Technopack Ltd, operates a plastic injection moulding plant with HUSKY PIM. Since reducing operation and maintenance costs were the focus areas for Manjushree, it was seeking a more cost effective and innovative solution with the aim of maximising productivity through enhanced equipment performance. This case study exemplifies how the right hydraulic oil can improve plastic injection moulding operators to increase productivity, reduce unscheduled downtime and improve the energy and cycle efficiency of their machinery.
Seeking a solution
Manjushree turned to ExxonMobil’s Field Engineering Services (FES), who are a team of technical experts working closely with manufacturing companies offering them advice on best-in-class lubrication and maintenance practices. ExxonMobil engineers assessed onsite usage conditions, consulted closely with Manjushree’s engineering personnel to understand the company’s lubrication requirements. Based on their test results, they recommended Mobil DTE 10 ExcelTM 46 to replace the previous hydraulic oil for increasing the energy efficiency & improving the performance of oil to reduce the operation & maintenance cost of the equipment. Mobil DTE 10 Excel 46 is an ISO Viscosity Grade (VG) 46, non-zinc, anti-wear hydraulic fluid. Its shear stable, high viscosity index (VI) allows for a wide operating temperature range maintaining maximum hydraulic efficiency and component protection at both low and high temperatures.
Switching to MobilTM hydraulic oil for increased energy efficiency, increased output and reduced operating and maintenance costs
The use of Mobil DTE 10 Excel 46 helped increase energy efficiency by 2% and brought about an annual savings of US $ 19950 for Manjushree. The product performance of Mobil DTE 10 Excel 46, alongside FES application expertise effectively helped the customer improve their productivity.
The Mobil DTE 10 Excel™ Series are high performance anti-wear hydraulic oils specifically designed to meet the needs of modern, high pressure, industrial and mobile equipment hydraulic systems. Mobil DTE 10 Excel provides reduced power consumption or increased machine output, resulting in monetary savings. The Mobil DTE 10 Excel 46 lubricant which is a part of this range helps keep hydraulic systems cleaner, extending machine reliability and helping increase productivity through improved machine availability.
For Manjushree Technopack Ltd., the upgrade to Mobil DTE 10 Excel 46 proved to be an ideal opportunity to take advantage of the benefits offered by the hydraulic oil’s advanced formulation. In particular, Manjushree was excited with the results seen from ExxonMobil’s comprehensive tests. It was observed that the changeover to Mobil DTE 10 Excel 46, resulted in improved hydraulic efficiency which helped in reducing energy consumption. A simple change of lubricant from a general market version to Mobil DTE 10 Excel 46, helped address Manjushree’s energy consumption reduction goals.
Energy and productivity benefits
With the completion of the lubricant change, Manjushree has responded saying, “The advice to switch to Mobil DTE 10 Excel 46 has helped in gaining energy efficiency which helped in productivity improvement”.
The composite benefits achieved by using Mobil DTE 10 Excel 46 are as follows:
- Mobil DTE 10 Excel 46 provided efficiency gains up to 2%
- Potentially reduced energy consumption or increased system responsiveness
- Reduced oil consumption
Speaking on ExxonMobil’s success in providing a customized solution to Manjushree’s requirements, Mr. Imtiaz Ahmed, Asia Pacific Mobil SHC Brand Manager, ExxonMobil Lubricants Private Limited said, “Mobil Industrial Lubricants supports customers with unmatched industry expertise and technical services, unsurpassed global supply capability, proven oil-analysis programs, and comprehensive builder approvals. Our Mobil DTE 10 Excel 46 provides outstanding hydraulic system efficiency, a high degree of fluid durability as well as ultra-keep clean performance. The results delivered for Manjushree is a perfect example of how ExxonMobil’s technology leadership and exceptional application expertise can deliver significant financial value and facilitate increased efficiencies and productivity”
About Mobil DTE 10 ExcelTM
Mobil DTE 10 Excel series provides “ultraclean” performance which helps in keeping systems clean up to 3 times longer than competitive hydraulic fluids. This is due to Mobil DTE 10 Excel Series hydraulic oil’s “hydraulic oil balanced formulation”. In Mobil’s proprietary laboratory test, Mobil DTE 10 Excel series has shown improved thermal stability. Better oxidative and thermal stability means the oil holds up better to higher temperatures which lead to longer oil life and reduces sludge type deposits or varnishes. Again, better thermal stability properties provide longer oil life and fewer sticking servo valves.
For more information on Mobil Industrial’s range of lubricants and services, visit mobil.com/industrial
The term “ExxonMobil” is used for convenience only, and may include Exxon Mobil Corporation or any of its affiliates.
