A specialized MEP project for YKK, the world's leading zipper manufacturer, focusing on designing and installing a high-efficiency compressed air system and a comprehensive fire detection and suppression network. The primary objective was to enhance production efficiency and uptime by delivering reliable, high-quality compressed air while ensuring the entire facility meets stringent international safety standards.
Client
YKK Pakistan (Pvt.) Ltd.
Location
Karachi, Pakistan
Year
2023
A Complex Engineering Puzzle
YKK's manufacturing process is heavily reliant on compressed air for pneumatic machinery. Their existing system was inefficient, leading to high energy costs, and suffered from pressure fluctuations that impacted production quality. Furthermore, the facility required an upgraded fire safety system to protect high-value automated machinery and raw material storage, ensuring compliance with both global corporate safety mandates and local regulations.
Innovative & Efficient
We engineered and installed a state-of-the-art, energy-efficient compressed air system centered around Variable Speed Drive (VSD) rotary screw compressors. This system automatically adjusts its output to match real-time air demand, minimizing energy waste. The solution included a complete air treatment package with refrigerated dryers and multi-stage filtration to deliver clean, dry air, protecting sensitive equipment. In parallel, we deployed a zoned, addressable fire alarm system integrated with heat and smoke detectors, along with a wet-pipe sprinkler system tailored for the production and storage areas, ensuring rapid detection and response.
Key Project Outcomes
Reduced energy consumption related to compressed air generation by over 30% using VSD technology.
Eliminated production defects caused by air pressure drops, increasing overall equipment effectiveness (OEE).
Achieved 100% compliance with NFPA 13 (Standard for the Installation of Sprinkler Systems) and local fire codes.
Improved air quality to ISO 8573-1 standards, significantly reducing maintenance needs for pneumatic equipment.
“Reliability is everything in our business. The new compressed air system has provided unmatched stability to our production lines, and the energy savings are substantial. Their team handled the entire project, including the critical fire safety upgrade, with exceptional professionalism and technical skill.”
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