In the temperature- and humidity-controlled workshop of Yubang Textile Technology in Chengtou Town, Fuqing, Fujian Province, the air conditioning system operates year-round without interruption.
As a leading enterprise in the domestic high-end functional chemical fiber knitted fabric industry, Yubang has extremely high requirements for temperature and humidity control in its production environment. The quality of every yarn in the workshop depends on the stable operation of this system. However, at the same time, the energy consumption of the water pumps has become a significant expense in operating costs.
“When there are many orders, we run at full capacity; when there are few orders, some areas are shut down. No matter how we adjust the water pumps, we always feel that the energy consumption is not going down,” recalled Yubang’s engineering manager. What worries him even more is that the company has planned a second phase of expansion. With the addition of main equipment in the future, will the existing water pump system be able to handle it?
On-site “diagnosis,” seeking answers from the source
To address these issues, the Kaiquan technical team did not rush to provide solutions but first conducted a site visit.
In the workshop, they saw Yubang’s dilemma: on the one hand, ensuring stable temperature and humidity to meet production process requirements; on the other hand, hoping to minimize operating energy consumption. Large load fluctuations are precisely the Achilles’ heel of traditional water pump systems—efficiency drops sharply under low loads, yet electricity costs remain high.
“The customer’s needs are clear, but conventional selection methods rarely address them all,” admitted a Kaiquan technician. “We had to find a solution at the system level.”
The team carefully inspected the piping system and discovered that the local resistance losses caused by the Y-type filters and check valves in the traditional design were too large, leaving room for optimization. Simultaneously, the inability of a single water pump to adapt to load fluctuations was also a major cause of high energy consumption.
Once the root cause was identified, a solution became clear.
Four-Step Optimization, Thinking One Step Further for the Customer
1. Low-Resistance Components, Reducing Energy Consumption at the Source
Replacing the traditional Y-type filter with a low-resistance filter and using a low-resistance check valve. These two adjustments, seemingly insignificant, effectively reduced local resistance in the piping, reducing the required pump head at the source, and consequently lowering the installed power.
2. Combination of Large, Medium, and Small Pumps, Intelligently Matching Load
To cope with the characteristics of large load variations, a combination of large, medium, and small pumps from the GXS high-efficiency intelligent modular pump set was adopted. The three pumps are automatically optimized through an intelligent control system, automatically matching the optimal operating combination based on real-time operating conditions—multiple pumps operate in parallel under high load, and single pumps operate under low load, ensuring the system always operates in the high-efficiency zone within a wide load range of 15% to 120%.
“It’s like equipping the workshop with an intelligent gearbox; it automatically selects the best gear when operating conditions change.”
3. Skid-mounted delivery, simplifying on-site installation.
The entire set of equipment adopts a skid-mounted design, prefabricated in the factory, with all piping, valves, and control systems fully integrated. After delivery to the site, only the inlet and outlet water pipes need to be connected for rapid use, with a rational layout.
At the same time, standardized factory integration effectively avoids the safety hazards caused by on-site welding and cutting operations, ensuring controllable installation quality and a neat and aesthetically pleasing appearance, saving customers time and effort.
4. Advance planning for Phase II expansion.
Considering Yubang’s future capacity expansion plans, Kaiquan has pre-planned the piping and valves required for the Phase II main unit in this design. “The road is already paved before the equipment is installed.” When adding new units in the future, they can be directly connected without any modification to the existing piping. The Story Behind the Data
After the project was put into operation, all indicators exceeded expectations.
✅ Energy saving rate of 28.1% – This is the most direct feeling from customers. Annual electricity bills were nearly 30% lower than in previous years.
✅ Wide high-efficiency range of 15%~120% – Regardless of the volume of orders, the water pumps always operate within the high-efficiency range, eliminating headaches caused by load fluctuations.
✅ Level 1 energy efficiency for the entire unit, noise level of 70dB, better than the Class A standard – The workshop is much quieter, and operation is more stable.
Since their commissioning, the GXS600-26 and GXS800-20 modular pump sets have operated stably with a zero failure rate. The pre-reserved interfaces for Phase II also reassured Yubang’s engineering manager: “We won’t need to bother with piping during future expansion; we can just install the equipment directly, saving us a lot of trouble.”
From site surveys to solution optimization, from low-resistance components to intelligent matching of pumps of all sizes, from skid-mounted delivery to Phase II pre-reservation—the GXS high-efficiency intelligent modular pump set is more than just a piece of equipment.
It’s a system solution, and more importantly, a thoughtful commitment to “thinking one step ahead for the customer.”
Yubang’s story continues. As Phase II expansion progresses, the pre-reserved piping and valves will soon come into play.
And this is precisely what Kaiquan has always believed: good products solve current problems, and good solutions accompany customers further.
