As part of our compressed air optimisation initiative, an airlock system was installed across all pneumatic lines to address air leakages in the filling area. This intervention significantly enhanced system integrity and operational efficiency. Additionally, one of the air compressors were replaced with a lower hp compressor basis the reduced losses. These measures led to a 15% reduction in compressor energy consumption – equivalent to approximately 50,000 kWh annually – with continued system improvements further increasing estimated energy savings.

To enhance operational efficiency and reduce energy consumption, motor controls for Basket Mills were integrated into the Distributed Control System (DCS). Previously operated manually, the mills experienced runtime losses and limited process visibility. Electrical and instrumentation upgrades now enable centralised control and monitoring via the DCS, improving process oversight and responsiveness.

Mixers were upgraded through blade design optimisation, significantly improving mixing performance. Previously, suboptimal blade placement caused inadequate vortex formation, foaming, and extended mixing times. By adopting efficient design by expanding blade span from 280 mm to 480 mm and reducing blade sets from four to two, the mixers now handle all product types (bases, shades, whites, and primers) without splashing or lumping. This upgrade has reduced mixer cycle-time by 20 minutes per batch and delivers energy savings.

Other key energy initiatives:

Egypt: LED retrofits and motion sensors within the premises further contributed to lighting efficiency.

Mirsarai, Bangladesh: Automation of grinding equipment and cold well pumps via DCS integration saved over 4,700 kWh. Motion sensors and false ceiling installations reduced AC load and lighting power consumption.

Gazipur, Bangladesh: Booster pump control, timer automation in TSD, and lighting optimisation saved over 18,000 kWh.

UAE & Oman: Replacement of fixed-speed compressors with VSD types and segregation of chiller circuits resulted in over 1,00,000 kWh in combined savings.

Fiji: VFD installation on HSD motors reduced annual consumption by 5,703 kWh.

Bahrain: Energy saving control units across 46 ACs led to monthly savings of 1,600+ kWh.

A rainwater harvesting project was implemented across both Nepal plants. An efficient RWH system was developed by analysing the region’s annual rainfall potential and total rooftop area. A total of 355 KL was harvested and utilised for different plant operations. The initiative significantly surpassed its original target, with rainwater reuse far exceeding expectations, and was further extended to units in Bangladesh & Sri Lanka. The total rainwater harvesting capacity is projected to be more than 2,000 KL and reflects AP Global’s commitment to environmental stewardship and resource efficiency.

To enhance cleaning efficiency and reduce material loss, tub furbishing was implemented in the water-based section by buffing the inner surfaces of 1 Kl tubs. Previously, cleaning each tub required approximately 65 litres of water and 25 minutes of labour, with around 1 litre of paint lost due to sticking. After furbishing, the smoothened surfaces prevent material from sticking, reducing water usage by up to 20 liters, saving up to 500 mL of paint per cleaning and improve overall operational efficiency

A Solvent Recovery Plant (SRP) was installed to recover xylene from mixed solvent waste. With recovery infrastructure now in place, reclaimed xylene is reused in operations, cutting down fresh solvent purchases and minimising hazardous waste.