Pumps, fans and compressors consume about 75% energy. If AC drives were employed in every feasible application, global electrical energy consumption will be reduced by around 10%, which amounts to huge power saving. In this interview with ITJ, Mandar Vaijanapurkar, Head - Sales & Service, Danfoss Drives, India Region, elaborates on challenges faced by manufacturing industries (especially textiles) and how AC drives can help reduce some of the pain points of the industry.

How is Danfoss serving the textile industry in India?
Danfoss leverages its years of expertise in India for energy savings solutions throughout the entire lifecycle in textile manufacturing. Danfoss’ reliable AC drives and soft starters are suitable for varied applications in the textile industry. The company offers tailored solutions which include heat-exchange concepts to meet tough textile environment for wobble and winders, advanced motion control functionality along with basic electromagnetic compatibility (EMC) performance. Standard built-in features and dedicated functionality makes Danfoss solutions an ideal choice for textile applications.

What are the applications of AC drives in the textile industry? What are the advantages of using AC drives?
AC drives help in accelerating the performance of the textile industry, smooth starting, reduced start current, flexible speed change for higher production and controlled ramp down in case of power loss. AC drives handle wide range of supply voltage variation.

AC drives enhance the quality of the yarn, improves process uptime with less yarn breaks and throughput for higher processing speed and reduced downtime. Drives offer an efficient solution in enhancing process and energy efficiency in textile industry, right from raw cotton to yarn, weaving, processing, and humidification along with typical savings up to 15-40% of the electrical energy consumption. ??

What are the USPs of Danfoss AC drives (especially with respect to their application in the textile industry)?
In the textile sector some of the applications require precise motion control performance. Danfoss drives play an integral role in providing maximum uptime and robust performance by minimising the cost of repair and maintenance. Additionally, the modules, components, and functionalities facilitate process optimisation in the textile industry. There can be loss of production time along with costly delays at the time of re-establishment of processes due to unexpected stoppage.

Danfoss AC drives are designed to avoid unplanned stops, changing power quality, and a regulated ramp-down in the event of a power outage. These drives are built with precision control through built-in intelligence and offer flexible configurable choices.

How important is the role of AC drives in improving (enhancing) the performance of compressors?
The AC drives improve the performance of compressors in refrigeration systems and air compressors. With energy being one of the largest cost factors, drives help in adjusting the equipment capacity to the actual heat load and process needs. Utilisation of drives helps in significant lower energy consumption and lower operation and maintenance costs for compressors.

Is the rising need for automation (& automated machinery) in the textile industry leading to more demand for AC drives? If yes, could you please elaborate?
Electricity accounts for 20% of global energy use. Electric motors consume more than half of all electrical energy. Pumps, fans, and compressors consume 75% energy. If AC drives were employed in every feasible application, global electrical energy consumption will be reduced by around 10%, which amounts to huge power saving.

AC drives are the most efficient way of adjusting the speed of electrical motors to match load demand in fan and pump applications. Even minor changes in motor speed might result in huge variations in energy consumption. They are carefully disguised, yet they play a significant role in modern, everyday life by making the globe and our way of life more sustainable.

What are the key challenges faced by the textile industry today? How is your company helping them overcome some of these challenges?
The textile industry today requires accurate control measures, robust and reliable products that optimise energy savings and reduce lifecycle costs. A high temperature and often unclean and dusty environment can make working conditions difficult in the textile industry, and downtime can be costly.

The Danfoss AC drives are built to withstand temperatures as high as 50°C. A variety of heat-exchange concepts are available to meet a wide range of requirements (cold-plate, fan-cooled, panel through-mount, with removable fan for external air cooling). The coating on PCBs prevents corrosion caused by humidity, lint, and aggressive chemicals. The enclosure prevents dust particles from entering in various degrees (up to IP 66).

It is crucial to optimise ambient variables- humidity and temperature during critical phases of the production process. By controlling water pumps and air fans, Danfoss' AC drives help improve yarn quality, process uptime, throughput, and energy efficiency (through faster processing and less downtime).

What are emerging trends in AC drives (especially with respect to application in the textile industry)?
AC drives with low energy consumption offer a significant return on investment and efficiency is the primary growth driver of the market. Increasing industrialisation and urbanisation have resulted in an increase in the demand for automated and motorised equipment. Additionally, modern infrastructure facilitates the use of AC drives, leading to an increase in their sales worldwide.

Apart from variable frequency drive (VFD) efficiency, the motor efficiency is more vital for overall system efficiency resulting into higher power saving. Higher efficiency motors like PMSM (IPM, SPM motors), Reluctance motors (Sync Rm, PM Sync Rm) are used. Danfoss VFDs can drive all types of these advanced high-efficient motors and thus ensure high system efficiency.

Will the Indian government's push towards man-made fibre (MMF) and technical textiles present new opportunities for companies like Danfoss? If yes, please explain.
Since the company began its independent operations in India, Danfoss India has been focusing on quadrupling its localisation efforts with respect to production and supply chain capabilities.

A strategic collaboration between the government and organisation is imperative for the growth of the Indian textile sector. The Indian government’s initiatives such as the PLI scheme launched in 2021 helps in boosting the manufacturing, enhancing exports, and attracting investments to the sector. Such initiatives are very helpful in attracting new opportunities for us as well. It will help us to drive the Indian textile industry with a focus on accelerating the “Make in India” initiative through enhanced technological and sustainable solutions.

What are your plans to further tap the textile industry in India?
With a focus on a steady growth of the Indian textile industry, Danfoss India aims to build fresh avenues for collaborations with the industry for enhancing the testing capabilities at par with the global standards and build innovative solutions. We have innovative solutions at our behest with an aim to push the technological boundaries and further tap the opportunities.

E-Textile is an emerging sector that is expected to grow at a rate of 30%. Since majority of Danfoss’ applications are sensor based - IOT, AR, VR, AI, and cloud computing will create a high impact in the future. Danfoss’ digitalization capabilities will put its customers ahead of the curve. Our expertise in integrated energy system in a hybrid mode, makes it possible for our partners to optimise their energy needs during peak and critical periods for seamless operations. In the wake of energy efficient regulations and standards being intensified, Danfoss products comply with the strictest of requirements world over. Danfoss will continually develop innovative solutions that ensure environmental sustainability, high energy efficiency and be a preferred decarbonisation partner for our customers to engineer tomorrow's India in a sustainable manner.