Variable speed drives increase uptime in chemical plant

Nimbasia Stabilizers, an Indian manufacturer of metallic stearates and other specialty chemicals, supplies additives to the pharmaceuticals, plastics and rubber sectors. Its production facility in western India operates almost continuously to meet domestic and export demand while maintaining strict quality standards.

The manufacturing of metallic stearates involves drying, grinding and conveying processes that generate significant amounts of fine dust. Over time, these particles accumulated on conventional variable frequency drives (VFDs), affecting cooling performance and electronic components. The result was repeated drive failures and unplanned downtime, directly impacting productivity and maintenance costs.

To support its objective of zero-defect production and stable round-the-clock operation, the company sought a more robust variable speed drive solution capable of operating reliably in dusty environments.

Selection of a dust-protected packaged drive
To address these challenges, Nimbasia deployed ABB’s packaged variable speed drives across multiple applications, including mixers, grinding mills and blowers. The selected solution integrates a disconnect switch and protective fuses within a compact unit, enabling safe isolation during maintenance and built-in protection against electrical faults.

A key selection criterion was the IP55-rated enclosure, designed to protect against dust ingress and moisture. This level of protection was critical for ensuring reliable operation in the plant’s harsh processing conditions. By preventing contamination of internal components, the drives reduce the risk of overheating and electronic failure.

According to Ravishu Mittal, Partner at Nimbasia:
“ABB’s drives enabled us to run longer, operate cleaner, and deliver better, in line with our vision for sustainable, high-quality manufacturing.”

Compact design reduces installation constraints
Beond environmental protection, installation flexibility played an important role. Traditional IP55 drive panels are often bulky and installed away from motors, requiring longer cable runs, additional protection measures and more floor space.

The packaged drives’ compact, panel-less IP55 design allowed installation closer to the driven equipment. With essential components integrated into a single unit, the footprint was significantly reduced compared to cabinet-based systems of similar power ratings. This minimized wiring, shortened installation time and supported compliance with Indian electrical regulations.

The reduced complexity of the drive setup also simplified commissioning and maintenance activities.

Operational results and return on investment
Since commissioning in January 2024, the plant has reported continuous operation without a single drive failure. The elimination of unplanned stoppages has led to measurable cost savings and improved process stability.

The investment achieved payback in less than three months, primarily due to avoided downtime, lower maintenance interventions and improved operational continuity.

In addition to reliability gains, the variable speed drives contribute to optimized energy use, controlled motor operation and enhanced process stability across production stages. For a plant operating under demanding environmental conditions, the upgrade supports both productivity and equipment protection objectives while strengthening long-term operational resilience.

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