Sri Lanka

A selection of the successful actions taken by pioneer companies in Sri Lanka to increase efficiency in their company operations can be found below. The following actions have led to savings in company costs for electricity and fuel:

  1. Continuous feeding of GI sheets by Lak Steel has led to an elimination of the end piece wastage in their pipe production process. The resulted benefits include cost savings of LKR 864,000 per annum and 600 kg of material saving. (Case Study - Cost Savings Material 1)
  2. Rectification of leakage points and replacement of damaged hoses by Orel Copper reduced the air leakages in their commpressed air distribution system by 8%. The resulted benefits include cost savings of LKR 35,500 per annum and energy saving of 2,950 kWh. (Case Study - Electrical Savings - Compressor 1)

  3. Rectification of leakage points and accurate power logging by a hot rolling complany reduced the air leakages in their commpressed air distribution system. The resulted benefits include cost savings of LKR 7,600,000 per annum and energy saving of 691,700 kWh. (Case Study - Electrical Savings - Compressor 2)
  4. Installation of transparent sheets in their factory floor has allowed an aluminium extrusion company to let natural light in and discontinue using high-power sodium vapour lamps during the day. The resulted benefits include cost savings of LKR 77,000 per annum and energy saving of 7,000 kWh. (Case Study - Electrical Savings - Lighting 1)
  5. Replacing the two-position actuator controller with a multiple-position controller has led to the size of the feeder opening to be reduced to a minimum. This has reduced the heat losses in the induction furnace at the Copper Melting & Wire Drawing, thereby helping them save LKR 175,865 per annum and reduce their energy consumption by 15,467 kWh. (Case Study - Electrical Savings - Loss Reduction)
  6. Replacement of utility electricity meter based on power logging verification helped a roofing sheet and GI pipe manufacturer overcome their erroneous billing and save LKR 834,000 per annum. (Case Study - Electrical Savings - Mains Metering)
  7. Repairing a capacitor bank helped Swisstek Aluminium restore a healthy power factor. The resulted benefits include reduce in demand by 75 kVA and cost savings of LKR 990,000 per annum. (Case Study - Electrical Savings - Power Factor 1)
  8. Reducing the opening of the powder curing oven door to the optimum level helped Electro Metal Pressings reduce their heat losses. The resulted benefits include cost savings of LKR 120,000 per annum and energy saving of 1,200 LPG kg. (Case Study - Fuel Savings - Loss Reduction 1)
  9. Unlike before, billets produced from induction furnace were fed to reheating furnace before the former cooled down. The reduced energy demand helped a hot rolling company save LKR 3,078,000 per annum in costs and 34,200 l (HFO) of fuel. (Case Study - Fuel Savings - Loss Reduction 2)
  10. Replacement of LPG gas burner in a powder coating oven has helped the powder coating industry adjust the burning rate. The resulted benefits include cost savings of LKR 157,300 per annum and energy saving of 1,513 LPG kg. (Case Study - Fuel Savings - Loss Reduction 2)
  11. Improved powder transfer efficiency through adjusting the charging voltage of the powder and increasing the distance between guns and profiles. (Material Saving - Changes in Setup)
  12. Improved working environment through 5S implementation (5S Implementation)
  13. Variable Frequency Drive (VFD) was installed to control the CT fan operation based on the inlet water temperature. When inlet temperature is low, VFD slows down the fan thus saving energy. (Energy Saving - Installing VFD)