“This is a very effective substitute for VFD under certain circumstances. It will make the VFD system even better when the VFD system is fitted onto this. So, this is a much broader system compared to VFD,” Dr. Jairam Varadaraj, Managing Director, Elgi Equipments Ltd said at an event to announce the launch of the company’s new innovation.
The new system automatically adjusts compressor output to real-time plant demand by smartly recirculating airflow within the machine. This ensures delivery always equals demand, helping industries save up to 17 per cent in energy consumption while improving equipment reliability and extending service life.
The Demand=Match system is now available in India as a factory-fit option on ELGi’s EG and EQ series compressors, with details on regional availability, pricing, and retrofit compatibility available from local ELGi representatives. “We are launching it in India this month, and we will launch it in the rest of the world in April next year,” he added.
“Compressed air is the fourth utility in every factory, yet demand is never constant. Most factories rely on fixed-speed compressors that deliver constant output even when demand drops. The Demand=Match system brings dynamic intelligence to these machines, helping customers save energy, reduce wear, and improve uptime without heavy capital investment,” said Varadaraj.
In industrial plants, compressed air demand fluctuates throughout shifts. Conventional fixed-speed compressors typically cycle between cut-in and cut-out pressure bands, resulting in energy losses, pressure overshoots, and stress on critical components. ELGi’s Demand=Match system addresses these challenges by eliminating unnecessary cycling, ensuring stable pressure and smoother operations even under varying demand conditions.
The system promises significant benefits for customers. Field test results indicate energy savings of up to 17 per cent in typical operating profiles. Reliability improves as reduced cut-in and cut-out cycles lower mechanical stress and component wear, while capital-light implementation ensures longer equipment life. Lower energy use also contributes directly to reduced CO₂ emissions, making the system a sustainability-friendly option.
In addition, ELGi is offering extended warranties of up to 10 years on EG series airends and five years on EQ series.
“The system continuously monitors pressure and modulates airflow through smart recirculation. It delivers exactly what the plant needs—no more, no less—ensuring smoother operation and lower energy use,” added Dr. K. Venu Madhav, Executive President – Product Excellence & Innovation at Elgi Equipments.
The technology is part of ELGi’s strategy to provide differentiated, value-driven solutions that lower total cost of ownership and enhance sustainability for customers across industries such as textiles, automotive, pharmaceuticals, food and beverage, electronics, and general engineering.
This new technology is applicable across the entire spectrum of screw compressors. “We are not changing lubricated screws, but we will bring it for VFD as well,” said Varadaraj.
