Customer Right Approach for Compressor Maintenance
Artistic Milliners (Pvt.) Ltd. is an o rganization focused on manufacturing and exporting premium quality denim products in a fully vertically integrated textile set-up, having the production capacity of 36 Million meters per annum. No less than twenty (20) Atlas Copco oil-free screw compressors of ZR series and refrigerant dryers of FD series are installed in its denim units # 2 and # 5 in Karachi, out of which 16 machines are under Atlas Copco Annual Preventive Maintenance Contract successfully for the 3rd year while 4 machines are newer and still under warranty.
Artistic Milliners has shown its loyalty towards Atlas Copco compressed air solutions from time to time and is possibly the most concerned Atlas Copco customer towards timely and proper maintenance of its compressors and dryers; all credit goes to its decision makers and field staff for their ‘no-compromise’ approach towards machine maintenance. Their well-maintained machinery and probably the most ideal compressor room in Pakistan, are evident of their commitment to quality assurance. Recently, major overhaul of their first ZR-250 compressor was performed by Atlas Copco Karachi service team in unit 5 after completion of its 40,000 running hours. It included replacement of consumables/wearing parts in Inlet Valve, Drive Shaft, Oil Pump, Coolers, Silencer, Oil, etc. along with replacement of complete HP element with its bearing and bearings of Drive Shaft. A heavy cost was incurred in overhauling of this compressor but the result was better than ever. Since the replacement of bearings and consumables reduced friction, amperes were saved on the compressor along with elimination of HP screw element deration of approximately 4 to 5%.
On a safe estimate, this timely maintenance activity will save Artistic Milliners unit 5, a staggering PKR 1.5 to 1.9 Million approx., each year which was previously wasted due to HP element deration and bearing resistance. The payback of investment on major overhaul of this compressor will positively be reached in between 1.5 to 2 years.