DSG International (Thailand) PLC, the manufacturer of disposable baby and adult hygiene products including BabyLove and Certainty, applied THERMAL-XR® graphene coating to an air-cooled chiller and measured a 9.53% reduction in energy use, translating to an estimated saving of 484,580 THB per year and a return on investment of under 1 year.
Case at a glance
| Customer | DSG International (Thailand) PLC |
|---|---|
| Location | Thailand |
| Site type | Hygiene products manufacturing plant |
| Equipment | Air-Cooled Chiller (with evaporative cooling system) |
| Brand | Trane |
| Capacity | 155 tons |
| Model | RATC155H |
| Equipment age | 10 years |
| Energy savings | 9.53% |
| Cooling efficiency | 0.965 → 0.873 kW/ton |
| Annual cost saving | 484,580 THB/year |
| Return on investment | < 1 year |
Background
Air conditioning and chiller systems are among the largest electricity users on an industrial site. Over time, condenser coils lose heat transfer efficiency, which forces compressors to work harder and increases energy consumption. At DSG, the cooling load is carried by a Trane air-cooled chiller with a capacity of 155 tons, which has been in service for 10 years. The chiller operates together with an evaporative cooling system, so it was already running at a relatively efficient 0.965 kW/ton before coating.
The solution: THERMAL-XR®
THERMAL-XR® is a graphene-enhanced coating from Graphene Manufacturing Group (GMG), designed to deliver superior heat transfer and protection for heat exchanger coils. The coating was spray-applied to the condenser coils of the air-cooled chiller, with no change to the equipment or the evaporative cooling system.
Results
Energy use was compared before and after coating:
- Electricity usage: 2,974 kWh/day before coating vs 2,690 kWh/day after
- Electricity cost: 423,732 THB/month before coating vs 383,351 THB/month after
- Carbon emissions: 484 tons CO2/year before coating vs 438 tons CO2/year after
- Cooling efficiency: 0.965 kW/ton before coating vs 0.873 kW/ton after
- Annual saving: 484,580 THB per year
- ROI: < 1 year
These results equal an energy saving of 9.53% and a reduction of about 46 tons of CO2 per year.
Takeaway
The DSG case shows that THERMAL-XR® adds savings even where other efficiency measures are already in place. On a chiller already supported by evaporative cooling, the coating still cut electricity costs by nearly 485,000 THB a year and paid for itself in under a year.
Want similar results at your site?
Get in touch with GMG to discuss your cooling equipment, or find a THERMAL-XR® applicator near you.
- Email: [email protected]
- Phone: +61 7 3063 6638
- Find an applicator: graphenemg.com/graphene-products/THERMAL-XR®/find-an-applicator
Measured energy savings presented in this case study are not predictors of future installation results. Estimated savings should be considered as estimates. Standard GMG disclaimer applies. All contents copyright © Graphene Manufacturing Group Ltd. All rights reserved.