An integrated textile facility may use more than 5,000 gear units. For example, in weaving, spinning and processing, approximately 2,500 of them may be spur- and bevel gears with a mean power of 5 kW, and another 2000 worm gears with a mean power of 15 kW.
With some 4,000 operating hours a year and a utilisation rate of 40 per cent, total power consumption is at approximately 68 Gwh. Replacing a mineral oil by a polyglycol special oil will increase the efficiency of all gears by roughly 5.25 per cent on average. The power saved thus totals 3.57 GWh, that’s 3,570 MWh – leading, based on India’s average mix of energy sources encompassing fossil fuels, nuclear power and renewables, to the emission of more than 3789 tons of CO2 per year. Based on an energy price of Rs. 5.10 per kWh, more than one crore rupees can be saved this way.