Case Study on impact of SUPERGAS on

Foam Extrusion

A case study of a customer who trusted and partnered with SUPERGAS for their LPG needs for consistent quality, safety compliance, and optimal production.

Abstract

In 2018, a leading fabric dyeing company in South India integrated a gas-burning stenter machine to enhance automation and minimize manual efforts. Initially powered by standard LPG, they upgraded to SUPERGAS's SR grade LPG in 2022, boosting both efficiency and fabric quality. This change has significantly improved safety standards, streamlined their fuel supply, and notably reduced operational costs, showcasing the advantages of SUPERGAS's SR grade LPG in the textile dyeing sector.

LPG for Foam Extrusion

Foam extrusion involves introducing a gas into molten polymer in an extruder to create foam. As the gas expands upon exiting the die, it transforms the polymer into a foam with either closed-cell or open-cell structure, varying by the process and materials. LPG is used as the foaming agent; it is injected into the polymer melt. It's selected for its ability to enhance the foam's cell structure, as well as to improve the consistency, quality, and uniformity of the final product.

Operational Impact Study

Before switching	After switching
The absence of clear instructions regarding safety protocols.	Timely safety audits and provided two safety training sessions on handling LPG.
Compromised finished product quality	SR grade LPG clean burning and even heat distribution improved the quality of finished product.
Lack of technical support from Local Supplier	Direct supply from SUPERGAS supported by dedicated customer service team improved overall operations.
Need to store excess cylinders in the Yard which is against the safety policies and norms.	We educated the customers on EACD, reducing the risk of unconnected cylinder storage at the LPG yard.
Lack of cylinder handling support, the cylinders were handled by Lucky Process team.	SUPERGAS had trained driver crew to load, unload, coupling and decoupling the cylinders, which improved the productivity of the customer.

Benefits of partnering with SUPERGAS

1. The customer experienced uninterrupted LPG supply with the installation of EACD, which resulted in seamless operations.
2. Complaint management system, safety audits and comprehensive safety training sessions reduced the safety concerns at workplace.
3. The customer observed improved product output with the supply of SR (Straight Run) grade LPG.
4. Our commitment and innovative solutions eliminated the need of dumping of excess cylinders in the premises.

Operational and Technical Impact Study

Before Switching to SUPERGAS	After Switching to SUPERGAS
The platform height was only 700 mm, and the customer was using a crane to unload LPG cylinders which is unsafe.	The platform height was elevated from 700 mm to 1100 mm from the ground level as per requirement for safe loading/unloading of cylinders.
Manifold near the factory valve and open window	Manifold with TRV & EFCV installed by SUPERGAS.
Foreign materials in the installation and only one earthing was provided.	Removal of foreign material inside/outside the LPG yard and addition of one more earthing pit.
No Safety distance as per IS guidelines. No copper jumpers and no ventilation.	Installation redesign as IS 6044 guidelines
No proper approach road	The LPG yard area was extended as per the required cylinder manifold installation for better accessibility
Violation of other statutory guidelines like lack of thermal relief valves, flow check valves, safety sign board and inadequate fire extinguishers.	SUPERGAS installed fences and cabling in the LPG yard, provided safety boards and fire extinguishers as per IS guidelines.

Benefits observed by the Customer

With technical clearance achieved, SUPERGAS commenced supplying SR Grade LPG, complemented by comprehensive safety training for operational and cylinder handling processes.
Furthermore, regular safety training and audits by SUPERGAS have fortified the customer’s confidence in maintaining a production environment free from safety concerns.
The customer now enjoys a secure LPG yard, enhanced end-product quality, diminished accident fears, minimal gas residuals, and consistent gas supply, marking a significant turnaround in operational efficiency and safety.