A world leader in the beverage industry aimed to improve combustion efficiency across its Indian plants, where boilers running on biomass and gas were consuming excessive fuel and adding to operational costs. The company also needed to strengthen its sustainability compliance without halting production. Following a comprehensive evaluation, the company partnered with Spectrum to implement an energy optimization solution proven to deliver quick and measurable results.They entrusted us to implement this in multiple plants across India.
Our Solution
Spectrum deployed its oxy-hydrogen gas (HHO) technology, installing high-capacity generators designed to produce pure energy from water. HHO gas was introduced into the boiler’s air intake, where it combined with combustion air and ignited with the primary fuel. This catalytic effect accelerated the combustion process and increased the concentration of triatomic gases in the furnace, enhancing radiant heat transfer and achieving near-complete fuel burn.
The integration was engineered for simplicity—our team connected the oxy- hydrogen system to the boiler’s temperature control loop for precise regulation.Air blower settings were kept constant, while HHO injection rates were optimized to maintain proper combustion ratios and achieve peak thermal efficiency.This process eliminated the need for costly structural modifications or production downtime.
Our Outcome
The plants recorded fuel savings of more than 10%, driven by higher steam-to-fuel ratios and consistent boiler performance. In addition to cost savings, the solution delivered significant environmental benefits, reducing emissions and supporting the company’s commitment to sustainable manufacturing.
