Polmar, the only company in Turkey concentrating on Expanded Polypropylene - EPP, distinguishes itself from its competitors in terms of price, technology, and quality. With unique design, production, and molding techniques, Polmar strives for continuous improvement and excellence, driven by its corporate culture.

In the factory of Polmar Automotive located in the Kütahya Organized Industrial Zone, an analysis conducted by the Lumian Energy team revealed that the existing compressor device operates at approximately 25% above its label values and continuously. The compressor, a critical machine in the facility's production, had a report accompanying a series of efficiency-enhancing suggestions to ensure its continuity and reduce energy consumption.

When examining Polmar's energy consumption through the Lumian EoT Platform, the following situations were encountered:

High power factor (PF) values were observed as negative in energy analyzers, prompting an examination of the energy consumption profile.

When PF values are negative, it was observed that the energy consumption profile is not in Quadrants Q1, Q2, Q3, and Q4.

This is an unusual situation; the energy consumption profile must be in Quadrants Q1, Q2, Q3, and Q4.

Air compressor machines operate above their capacities.

Compressor 1 Maximum power: 250 kW - Energy Consumption goes up to 300 kW.

Compressor 2 Maximum power: 90 kW - Energy Consumption goes up to 100 kW.

This situation is abnormal; when calculating the compressor requirement in facilities, it is usually done by leaving a 20% margin for efficient use. Here, the compressors operate at 120%, which is contrary to the norm. Air compressors, due to their nature, consume their lifespan by working in this way.

The existing air system in the facility should be examined and designed.

Recommendations for the facility:

1. Using the existing air system, an investment should be made in a pump called a BLOWER to transport raw materials to presses by air. This way, the load of this section will be taken from the main air compressors, relieving the existing compressors.

2. After calculating the air consumption of relevant sections and departments, one of the existing compressors should be moved closer to the section and department with intensive consumption, reducing the air transport distance. For example, presses. This way, the load of this section will be taken from the main air compressors, relieving the existing compressors.

Thanks to these recommendations, the total energy consumption of the facility decreased by 10%, and the health of the compressors, which are among the most important machines in production, was improved, extending equipment life, and reducing maintenance costs.

Polmar Business Development Manager Berke Yeni, experiencing the benefits of using the Lumian Energy Management System firsthand, also contributed significantly to the development of the software by providing suggestions to expedite operational processes.

Polmar Automotive Industry and Trade Inc. Lumian Technology Inc.