20% ROI — Efficiency You Can Measure, Returns You Can Trust

↑↑↑

Production

20%

Fuel Saved

0

Steam Traps

Challenges & Solution

Original situation

Baseline data showed 136 kg of fuel per ton of product from Nov ’24 – Jun ’25.

Steam traps and control valves caused condensate buildup, uneven heat transfer, and energy losses.

Objectives:

  • Reduce fuel cost per ton

  • Ensure consistent quality and drying

  • Implement solution with no downtime

Technical modification

i-Kcal engineered & commissioned Jetomat TurboHeat as a turnkey retrofit for the corrugator line.

  • Eliminated traps and steam losses

  • Boosted internal steam velocity and heat transfer

  • Delivered uniform surface temperature in dryers and hot plates

  • Installed with no downtime, ensuring uninterrupted production

The implementation of Baelz retrofit with Jetomat TurboHeat® in place of traditional control valves has resulted in approximately 20% fuel savings, elimination of steam traps, complete automation of heating & better drying quality.

The Jetomat® Turboheat® technology has proven to be an effective solution for enhancing energy efficiency and process performance.

Benefits of Jetomat Turboheat

  • Item description

Case Study Overview

Located in Morbi, Gujarat, a major corrugation hub, the plant produces high-volume corrugated sheets for packaging. Rising fuel costs and pressure on margins pushed the management to look for a solution that could cut energy use without disrupting production.

Result / Numbers / Matrices

Period

Fuel (kg/ton)

Baseline (Nov ’24 – Jun ’25)

136

July ’25

113

August ’25

108

16.8%

~22

~36

CO₂ Avoided (tons)

Saving % vs Baseline

–

Fuel Saved (tons)

–

–

Conclusion

This project demonstrates that proven technology + expert engineering = measurable ROI.
Jetomat TurboHeat, delivered by i-Kcal Systems, enabled the plant to cut fuel use from 136 to 108 kg/ton while maintaining consistent output and quality.

For corrugators, this is not just an efficiency upgrade — it’s a step toward sustainable, cost-competitive growth.

20.6%

~23

~38

Budget (Indicative)

The project was executed as a turnkey retrofit within a planned maintenance budget. The payback period is expected to be less than 18 months based on the 18–20% monthly savings.

Project Details

Location: Morbi, Gujarat

Technology: Steam system retrofit with Jetomat TurboHeat®

Industry: Corrugated Packaging

Company: Corrugator Plant (Confidential name with held)