How much energy does a VSD save on raffia tape bobbin winders?

The Energy and Resources Institute's (TERI) Ramnagar plastics profile says a variable speed drive (VSD) in place of a magnetic eddy current drive on bobbin winding can save 50 to 60 percent per 200 tapes winding. That is a cluster estimate, not a result for your line, so meter your winders before and after.

What TERI says

TERI's profile of the Ramnagar plastic cluster lists the bobbin winding drive as a place to save: using a variable speed drive (VSD) in place of a magnetic eddy current drive on bobbin windings can save energy to the extent of 50 to 60 percent per 200 tapes winding. The profile does not say what the 200-tape base refers to, so read the range as the size of the prize, not a guarantee.

The other measures in the same profile

• VSDs on motor-driven systems usually save 20 to 50 percent.
• A variable frequency drive on the extruder motor can cut power by up to 20 percent.
• A servo motor on injection moulding hydraulics saves about 30 percent and is named the best option.
• All-electric injection moulding machines can use 50 to 80 percent less energy than hydraulic ones.

Why winders are worth a look

An eddy current coupling sets speed by slipping, so much of the motor's power turns into heat when the bobbin runs slow. A VSD sets the motor's own speed instead. Winders often run all shift, so even a modest cut shows up on the monthly bill.

How to measure your own saving

1. Log the winder section's kWh for a normal week, with the kg of tape wound.
2. Fit the drive on one winder or one bank.
3. Log the same week again and compare kWh per kg wound.
4. Use your own figure for the payback, not the range above.

Example: winders using 18,000 kWh a month (example figures)

• Saving at 50 to 60 percent: 9,000 to 10,800 kWh a month
• Grid factor 0.675 kg CO2 per kWh (Central Electricity Authority, FY 2025-26)
• CO2 saved: 9,000 x 0.675 = 6.1 t a month, up to 10,800 x 0.675 = 7.3 t a month

Example numbers. The 50 to 60 percent is TERI's cluster estimate.

What Senseible does here

Senseible reads your electricity bills into monthly kWh and CO2, so a saving after the drive goes in shows up bill to bill. A sub-meter reading on the winder section sharpens it further.

• Ramnagar plastics cluster: energy and CO2
• Ramnagar pipe units: where the energy goes
• Your MSME carbon number

Sources: TERI and SAMEEEKSHA, Cluster Profile Report: Ramnagar plastic industries (2016), energy saving options

Last reviewed 2026-11-04. The savings are TERI's 2016 estimates; confirm against your own meter readings.