AIR KNIFE SYSTEM (Blower Assisted) : To run 12" knife with at 24,000FPM, 0.85 Kw Blower is required. Considering cost of energy of Rs.6/- per Kw-Hr; cost of running Blower for 8 Hrs, for 300 days per year. 0.85kw X 8 Hr X 300 days X Rs.6/- per unit = Rs.12,240/-
Air Knife System (Compressed Air Assisted) : To run 12" knife at 18,000 FPM 5 Kw Air Compressor is required. Considering cost of energy at Rs.6/- per Kw-Hr cost of running Air Compressor for 8 Hr for 300 days per year. 5kw X 8 Hr X 300 days XRs. 6/- per unit = Rs.72,000/-
Thermal Drying : 12" long Heater of 2 Kw Heater with small 200 watts blower is Required. Considering cost of energy at Rs.6/- per Kw- Hr cost of running Heater For 8 Hr for 300 days per year. 2.2 Kw X 8 Hr X 300 days X Rs.6/- per unit = Rs.31,680/-
Even if you have to replace existing Compressed air assisted Air Knife System or Thermal drying system, by scrapping the existing system, and installing a new Blower assisted Air Knife System costing Rs. 20,000/-,
Energy cost saving would pay off for System within 3 to 6 months, after which energy cost savings will be total profit.
If plant is running for triple shifts and whole year around, the payback periods will be much faster and savings will be even greater.