As industrial energy needs grow, efficiency and Automation are no longer luxuries but necessities. One food processing company in Karnataka understood this all too well when facing the limitations of manually feeding briquettes into their 6 Lakh kcal/hr thermic fluid heater. The solution? A strategic switch to biomass fuel Astillas combined with Steamax’s Auto Fuel Feeding Kit—a move that brought them measurable cost savings, better combustion, and operational stability.
The Challenge: Inefficient Manual Feeding and Rising Costs
For years, the company relied on manually feeding biomass briquettes, which meant:
- 15 tons of briquettes used per month
- Fuel cost of ₹9.5 per kg
- Monthly spend: ₹1,42,500
Manual feeding caused:
- Inconsistent combustion, resulting in uneven heat generation
- Frequent downtimes due to feeding delays
- High labour dependency and costs
- Fluctuations in product quality and energy output
It became clear that a change was needed—not just in fuel, but in the system itself.
The Steamax Solution: Biomass Astillas & Auto Fuel Feeding Kit
Steamax Envirocare stepped in with a two-fold upgrade:
- Switch from briquettes to Astillas – a low-moisture, low-ash biomass fuel that burns cleaner and more efficiently.
- Installation of the Auto Fuel Feeding Kit – designed for seamless and consistent fuel delivery into the thermic fluid heater.
This powerful combination ensured uninterrupted, high-efficiency combustion—maximizing fuel-to-heat conversion while drastically reducing operational downtime.
Implementation Highlights
- Automated Fuel Handling: The feeding system removed the need for manual input, minimizing physical labour and human error.
- Optimized Burn Rate: With Astillas’ finer size and better combustion properties, heat output became more consistent and controllable.
- Downtime Reduced: Automation ensured fuel was always available, reducing stoppages and improving uptime.
The Results: Tangible Savings
Results & Cost Savings:
| Parameter | Before (Briquettes) | After (Astillas) |
|---|---|---|
| Monthly Consumption | 15 tons | 10 tons |
| Cost per kg | ₹9.5 | ₹12 |
| Monthly Fuel Cost | ₹1,42,500 | ₹1,20,000 |
| Annual Fuel Cost | ₹17.1 Lakh | ₹14.4 Lakh |
| Annual Savings | – | ₹2.7 Lakh (15.8%) |
Before:
- 15 tons/month briquettes @ ₹9.5/kg = ₹1,42,500
- Manual feeding = higher labour costs + inconsistent heat
After:
- Fuel cost savings of 15.8%
- Lower consumption due to improved combustion
- Reduced labour dependency and increased workplace safety
- Improved product consistency due to a steady heat supply
What the Client Had to Say
“The transition from briquettes to Astillas with the Auto Fuel Feeding Kit has made a remarkable difference. We have seen reduced fuel costs, increased efficiency, and improved production reliability. Steamax Envirocare provided the perfect solution to optimize our heating system.”
Biomass: A Smarter, Cleaner Way to Run Industrial Heating
This case study is a wake-up call for industries still dependent on the manual feeding of briquettes or low-grade biomass. The future belongs to cleaner fuels and automated systems that don’t just promise performance—they deliver it. By embracing Astillas and Steamax’s Auto Fuel Feeding Kit, the food processing company in Karnataka proved that operational excellence and sustainability can go hand in hand.
Is your plant still stuck in manual mode? It might be time for an upgrade. Contact us today to explore how biomass and Automation can work together to unlock new performance levels.
