Maxion Wheels, a global manufacturer of steel and aluminium vehicle wheels, applied THERMAL-XR® graphene coating to an air-cooled chiller at its site in Thailand and measured a 15.85% reduction in energy use, translating to an estimated saving of 99,964 THB per year and a return on investment of under 2 years.
Case at a glance
| Customer | Maxion Wheels (a division of Iochpe-Maxion) |
|---|---|
| Location | Thailand |
| Site type | Wheel manufacturing plant |
| Equipment | Air-Cooled Chiller |
| Capacity | 36 tons |
| Equipment age | 15 years |
| Energy savings | 15.85% |
| Cooling efficiency | 1.860 → 1.565 kW/ton |
| Annual cost saving | 99,964 THB/year |
| Return on investment | < 2 years |
Background
Air conditioning and chiller systems are among the largest electricity users on an industrial site. Over time, condenser coils collect dust and lose heat transfer efficiency, which forces compressors to work harder and increases energy consumption. At Maxion Wheels’ site in Thailand, the cooling load is carried by an air-cooled chiller with a capacity of 36 tons, which has been in service for 15 years.
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 itself.
Results
Energy use was compared before and after coating:
- Electricity usage: 531 kWh/day before coating vs 447 kWh/day after
- Electricity cost: 52,557 THB/month before coating vs 44,227 THB/month after
- Carbon emissions: 86 tons CO2/year before coating vs 73 tons CO2/year after
- Cooling efficiency: 1.860 kW/ton before coating vs 1.565 kW/ton after
- Annual saving: 99,964 THB per year
- ROI: < 2 years
These results equal an energy saving of 15.85%, with the chiller using about 16% less power for every ton of cooling it delivers.
Takeaway
The Maxion Wheels case shows that coating an existing air-cooled chiller can restore efficiency and cut energy use by nearly 16% without replacing equipment, even on a unit that has been running for 15 years.
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.