Whole-line energy efficiency retrofit for rubber tire manufacturing plants
A tire manufacturer faced high overall energy consumption due to a diverse range of motor drive systems across its production line that operated independently without unified coordination. The project upgraded the drive systems for key processes—including mixing, calendering, and molding—by replacing legacy equipment with permanent magnet synchronous motors and variable frequency drives. An automated control system enabled synchronized multi-device operation. Post-retrofit results show significantly improved system efficiency, reduced overall energy consumption, and enhanced production stability and product consistency.
RESULTS
Transformation Results
SAVING RATE
Overall energy consumption reduction after retrofit
ENERGY COMPARE
Annual Energy Consumption Comparison (Unit: 10,000 kWh)
KEY METRICS
Integrated operation of the full-line drive system reduces overall energy consumption and enhances production line stability.
RELATED
Products and Solutions in this Project
Tire Production Line Automation Control
Automated Control and Intelligent O&M Solutions for Complete Rubber Tire Production Lines
Centered on Panpu PLC control cabinets and MCC switchgear assemblies, SCADA factory automation monitoring systems, and SaaS IoT cloud platforms, we provide turnkey automation control and equipment connectivity solutions for rubber tire and rubber-plastic product manufacturing plants. Our solution supports multi-PLC network topologies, multi-machine data acquisition, real-time energy consumption and operational condition monitoring, and mobile remote operations and maintenance.
Oil Pump Drive Control
Beam Pump Drive Control System Solution
Designed for beam pumping units in oilfields, this solution replaces the traditional asynchronous motor with pulleys and gear reducer using a TYCP5 series low-speed permanent magnet synchronous motor direct drive. Paired with the WD200 high-performance vector frequency converter and energy feedback unit, it enables four-quadrant operation and recovers energy during the downstroke. The system transmission efficiency increases from 81% to 92.12%, achieving an energy saving rate of 15%~40%.
JUMO Water Quality Analysis Sensors
JUMO offers a complete range of water analysis sensors covering pH/ORP, electrode and electromagnetic conductivity, dissolved oxygen, turbidity, disinfectants, and ammonia. As Europe's leading manufacturer of electrochemical sensors, JUMO brings over 1947 years of expertise in pH electrode glass technology. We provide multiple electrode series including ecoLine, BlackLine, tecLine, labLine, and ISFET, along with digiLine digital sensors. Turbidity measurements comply with DIN EN ISO 7027, and high-purity water conductivity comes with ASTM electrode constant certification.
JUMO Screw-in and Insertion Thermocouples
JUMO Screw-in and Insertion Thermocouples meet DIN 43710, DIN EN 60584, and ANSI MC96.1/ASTM E30. Temperature range: -200 to +1150°C. Available with Type B/J terminal boxes, integrated temperature transmitters, and replaceable thermowells. Ideal for industrial plants, thermal processing, and drying systems.
Wolong WD200 Series High-Performance Universal Variable Frequency Drive
Wolong WD200 Series High-Performance General-Purpose Variable Frequency Drives offer power ratings from 0.75 to 1000 kW. They support single-phase 200~240 V, three-phase 200~240 V, three-phase 380~480 V, and three-phase 660~690 V power supplies, driving three-phase asynchronous motors, permanent magnet synchronous motors, and synchronous reluctance motors. Features include V/F control, open-loop vector (SVC), closed-loop vector (FVC), and decoupled voltage-frequency control modes. Speed ranges are 1:200 (SVC) / 1:1000 (FVC). Output torque is 0.5% of rated at 0 Hz and 150% of rated at 200% Hz. Efficiency reaches up to 98%. Supports common DC bus multi-drive and four-quadrant applications.
Wolong Electric Drive WEPM5 Series Variable Frequency Speed Control Permanent Magnet Synchronous Motor
Wolong Electric Drive WEPM5 Series IE5 Efficiency Inverter-Driven Permanent Magnet Synchronous Motors, frame sizes 63 to 315, power ratings from 0.18 to 315 kW. Features high power density and constant torque output across a wide speed range. Available in aluminum or cast iron housing options.
SOLUTIONS
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TESTIMONIALS
Customer Reviews
Replacing the entire line motors and implementing variable frequency drives has significantly stabilized energy consumption curves in the mixing and vulcanization stages, with a clear month-over-month reduction in electricity costs.
Energy Manager, Tire Manufacturing Company
Energy Manager
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