The electricity bill arrives every month without fail. For die casting facilities running two or three shifts, that number climbs steadily. When your production manager talks about efficiency improvements, the finance team wants proof, not promises.
Here’s what actually happens when manufacturers switch to hybrid servo technology.
The Baseline Reality
Traditional hydraulic die casting machines consume power continuously. The hydraulic pump runs whether you’re injecting metal or adjusting parameters between cycles. A 500-ton hydraulic machine typically draws 45-50 kW during active operation and maintains 15-20 kW even during idle periods.
Calculate that across a two-shift operation. Sixteen hours daily, twenty-six days a month. You’re looking at roughly 18,000-20,000 units consumed monthly per machine. At industrial power rates in Gujarat averaging ₹7-8 per unit, that’s ₹1.3-1.6 lakhs per machine, per month.
Scale that to a facility running four machines. Annual electricity costs for just the die casting equipment cross ₹60 lakhs easily. Before you factor in melting furnaces, cooling systems, and auxiliary equipment.
What Changed After Vidyut Installation
A Rajkot automotive component manufacturer replaced two of their 600-ton hydraulic machines with Vidyut Series hybrid units in early 2024. They tracked power consumption carefully because the investment decision hinged on promised energy savings.
Month one showed immediate results. The hybrid machines consumed 28-32 kW during active cycles and dropped to 5-8 kW during idle periods. The servo injection system only draws power when actually moving, unlike hydraulic pumps that run constantly.
Their monthly consumption per machine dropped from 19,500 units to 11,800 units. That’s a 39.5% reduction, almost exactly matching the claimed specifications. More importantly, it translated to ₹54,000 saved monthly per machine, or over ₹6 lakhs annually per unit.
The numbers held steady across seasonal variations. Summer months with higher ambient temperatures showed slightly elevated consumption due to increased cooling requirements, but the differential between hydraulic and hybrid remained consistent.
Breaking Down Where Savings Come From
The injection system accounts for the largest efficiency gain. Servo motors respond instantly and only consume power during actual movement. Shot preparation, injection, and intensification happen with precise energy delivery. No continuous pump operation bleeding power between cycles.
Hydraulic systems still handle clamping and other high-force operations, but modern accumulator designs and optimized valve configurations reduce unnecessary energy draw. The hybrid approach uses hydraulic power only when and where it’s actually needed.
Temperature control improved too. Better injection consistency means fewer rejected parts requiring remelting. Less scrap translates directly to reduced furnace operation. One manufacturer noted their melting energy dropped by 12% simply because fewer parts failed quality checks.
Cycle times shortened by 8-15% depending on part complexity. Faster cycles mean more parts per shift with the same energy input. Productivity gains compound the efficiency improvements, making each unit of electricity deliver more finished components.
The Payback Math
The Vidyut Series typically costs 15-20% more than an equivalent tonnage hydraulic machine. For a 600-ton unit, that premium amounts to roughly ₹12-15 lakhs.
Factor in the ₹6+ lakh annual energy savings. Simple payback period comes out to 24-30 months. After that, it’s pure bottom-line improvement year after year.
But the calculation doesn’t stop at electricity bills. Reduced maintenance on the injection system adds another ₹40,000-60,000 annually. No hydraulic oil changes for that portion of the machine. Fewer seals and valves wearing out. Less frequent filter replacements.
Quality improvements reduce material waste. One hardware manufacturer reported their rejection rate dropped from 3.2% to 1.8% after switching to hybrid technology. For a facility consuming 50 tons of aluminum alloy monthly, that’s nearly 70 tons of material saved annually. At current metal prices, that’s another ₹25-30 lakhs staying in the business instead of going to scrap.
Real Facility, Real Results
A sanitary ware producer in Rajkot operates three Vidyut Series machines alongside two older hydraulic units. They keep both types running because different jobs suit different equipment, but the contrast shows up clearly in their monthly reports.
Total facility power consumption dropped 28% after the hybrid machines came online, even though production volume increased 15%. The energy cost per finished part fell from ₹47 to ₹31. That difference scales dramatically when you’re producing 50,000 pieces monthly.
Their maintenance schedule shifted noticeably. The hydraulic machines require attention every 800-1000 operating hours. The Vidyut units stretch that to 1500-1800 hours. Fewer unplanned stoppages mean better schedule adherence and fewer rushed overtime shifts to catch up on delayed orders.
Operator feedback surprised the management team. Workers prefer running the hybrid machines because the touchscreen controls are clearer and parameter adjustments happen faster. Training new operators takes less time. The smart HMI remembers job settings, so changeovers involve fewer manual inputs and less room for error.
Beyond the Spreadsheet
Energy savings show up in financial statements, but the operational improvements matter just as much. Better shot consistency means tighter tolerances. Reduced cycle times increase capacity without adding floor space. Faster parameter adjustment speeds up new product development.
One manufacturer used the capacity gains from their hybrid machines to take on a new customer contract without buying additional equipment. The ROI calculation suddenly included revenue growth, not just cost reduction.
Environmental impact matters more every year. Several export-focused manufacturers mentioned that European customers increasingly audit energy consumption as part of supplier qualification. Demonstrating 40% energy efficiency gains strengthens those relationships and opens doors to sustainability-focused brands.
What the Numbers Mean for Your Operation
Every facility has different production mixes, shift patterns, and power rates. Your specific savings will vary based on those factors. But the physics doesn’t change. Servo motors drawing power only during active movement will always be more efficient than hydraulic pumps running continuously.
Calculate your current monthly consumption per machine. Multiply by 0.4 to estimate potential savings. Factor in your local power rates. Add reduced maintenance and lower scrap rates. Compare that against the investment premium for hybrid technology.
For most manufacturers running consistent production volumes, the math works clearly in favor of upgrading. The Vidyut Series delivers on its efficiency promises because the underlying technology principles are sound and the real-world installations prove it consistently.
Energy costs aren’t dropping. Competition isn’t slowing down. Margins aren’t getting wider. Every rupee saved on electricity or maintenance flows directly to profitability. That’s the real number that matters when finance reviews the investment proposal.
Forty percent energy savings isn’t a marketing claim. It’s measured, verified, and documented across multiple installations. Your facility can achieve the same results with the right technology choice.
