Project Overview-4 Ton WNS Gas Steam Boiler for Garment Factory in Indonesia
- Project Location: Bandung, West Java, Indonesia
- Target Industry: Garment Manufacturing & Textile Finishing
- Boiler Model: 2 Sets Taiguo WNS4-1.0-Q High-Efficiency Package Boiler
- Primary Fuel Type: Pipeline Natural Gas (LNG Compatible)
- Commissioning Year: 2024
- Engineering Scope: Thermal System Redesign, Boiler Manufacturing, Export Delivery, and Complete On-site Installation
Technical Parameters & Specifications Of WNS Gas Steam Boiler for Garment Factory in Indonesia
A precise engineering configuration is the foundation of any successful industrial project. The table below details the exact manufacturing and design parameters for this Indonesian garment facility deployment:
| Parameter Item | Specification / Engineering Value | Technical Notes & Compliance |
| Boiler Type | Three-Pass Wet-Back Boiler | High thermal safety, low radiant heat loss |
| Rated Steam Capacity | 4 Tons per Hour (4 t/h / 2800kW) | Matches peak pressing and fabric setting loads |
| Design Pressure | 1.0 MPa (10 Bar / 145 PSI) | Provides stable pressure for high-speed ironers |
| Saturated Steam Temp. | 184°C | Ideal temperature to prevent fabric moisture water spots |
| Furnace Type | Wave-form Corrugated Furnace | Increases heat transfer area, absorbs thermal expansion |
| Smoke Tube Type | Threaded Fire Tubes | Disrupts laminar flow to maximize thermal absorption |
| Thermal Efficiency | 98.2% (with Condenser) | Reduces daily natural gas consumption significantly |
| Control System | Siemens PLC Touch-Screen System | Fully automated modulation with remote monitoring |
Customer Challenges: Energy Inefficiency in Bandung
Bandung is the heart of Indonesia’s garment and apparel manufacturing hub. A major garment enterprise here faced severe operational bottlenecks due to its aging thermal infrastructure. The factory operates multiple high-capacity fabric stenter frames, continuous garment pressing lines, and industrial steam ironers. This machinery requires an uninterrupted supply of highly dry, constant-pressure steam throughout a 24-hour production cycle.
However, the client’s existing low-efficiency boiler suffered from three critical problems:
- Severe Pressure Fluctuations: During peak morning shifts, the steam pressure frequently dropped from 0.8 MPa down to 0.5 MPa. This instability directly compromised the fabric finishing quality, leading to rejected garment batches.
- High Thermal Waste: The exhaust gas temperature of the old boiler exceeded 240°C. This meant a massive amount of paid energy escaped straight into the atmosphere.
- Frequent Structural Failures: The old dry-back boiler design caused frequent cracking in the rear smoke chamber refractories, forcing unexpected production shutdowns.
To maintain market competitiveness, the factory required a radical energy-saving upgrade. They needed a verified industrial boiler manufacturer capable of delivering a turnkey solution, spanning custom design to overseas mechanical installation.
Detailed Engineering Solution: Customized WNS Gas Steam Boiler for Garment Factory in Indonesia
Our overseas technical department conducted a thorough calculation of the plant’s dynamic hourly steam load profiles. To address their core challenges, Taiguo engineered a customized WNS4-1.0-Q three-pass wet-back gas steam boiler（WNS Gas Steam Boiler for Garment Factory in Indonesia）.
1. Wet-Back Structure vs. Old Dry-Back Design Of WNS Gas Steam Boiler for Garment Factory in Indonesia
We replaced the problematic dry-back configuration with a classic wet-back structure. In this design, the rear turning chamber is completely surrounded by boiler water. This layout eliminates expensive refractory brick maintenance, lowers structural stress, and maximizes back-end heat absorption.
2. Advanced Internal Heat Transfer Engineering Of WNS Gas Steam Boiler for Garment Factory in Indonesia
To optimize fuel utilization, we integrated a wave-form corrugated furnace. This geometry increases the radiant heating surface area by over 12% compared to smooth-walled drums. Following the combustion chamber, we installed specialized threaded fire tubes. The internal structural threads force the hot flue gas to rotate, disrupting the boundary layer and accelerating heat transfer to the surrounding water.
3. Integrated Condenser Heat Recovery Unit Of WNS Gas Steam Boiler for Garment Factory in Indonesia
We attached an advanced finned-tube economizer/condenser directly to the boiler flue gas outlet. This heat exchanger utilizes the low-temperature boiler feedwater to cool down the exhaust gas. It recovers both sensible and latent heat from the combustion emissions, dropping the final exhaust temperature to a low 85°C. This engineering upgrade instantly boosts overall thermal efficiency past 98%.
4. High-Dryness Steam Separation System Of WNS Gas Steam Boiler for Garment Factory in Indonesia
Garment pressing requires highly dry steam. Droplets in the steam line cause immediate water stains on premium apparel fabrics. Taiguo integrated a high-capacity internal steam-water separator grid inside the boiler drum. This ensures the output steam dryness consistently exceeds 99%, securing flawless fabric finishing.
On-Site Installation & Commissioning Process Of WNS Gas Steam Boiler for Garment Factory in Indonesia
A great boiler design requires precision execution on the factory floor. Under our explicit Boiler Design + Installation project scope, Taiguo managed the complete mechanical deployment on-site in Bandung, West Java.
& Boiler Positioning
Auxiliary Integration
& Safety Valve Tests
& Local Training
Fine-Tuning (24 Hours)
X-Ray Welding Exams
Our overseas engineering team executed the deployment through five rigorous stages:
- Foundation & Positioning Of WNS Gas Steam Boiler for Garment Factory in Indonesia: We supervised the concrete foundation leveling and positioned the 2-ton packaged boiler shell using specialized heavy rigging equipment.
- Piping & Auxiliary Integration Of WNS Gas Steam Boiler for Garment Factory in Indonesia: Our technicians completed the main steam header connections, installed the automated water treatment unit, and integrated the high-pressure feedwater pumps.
- Non-Destructive Testing (NDT) Of WNS Gas Steam Boiler for Garment Factory in Indonesia: To guarantee zero leakage, our certified inspectors conducted on-site X-ray welding examinations on all newly connected industrial steam pipelines.
- Hydrostatic Pressure Testing Of WNS Gas Steam Boiler for Garment Factory in Indonesia: We subjected the complete pressure boundary to a hydraulic test at 1.5 times the maximum design pressure (1.5 MPa), holding it stable to confirm absolute structural integrity.
- Burner Tuning & Automation Calibration Of WNS Gas Steam Boiler for Garment Factory in Indonesia: Our automation engineers calibrated the Italian-brand gas burner alongside the Siemens PLC control panel. We fine-tuned the air-to-fuel ratio across multiple load steps to ensure low NOx emissions and optimal fuel modulation during peak production hours.
Project Results Of WNS Gas Steam Boiler for Garment Factory in Indonesia: Measurable Operational ROI Data
The WNS steam boiler system delivered immediate, quantifiable financial and operational advantages right after commissioning. The data matrix below contrasts the client’s old setup against the newly engineered Taiguo system:
| Performance Indicator | Legacy Boiler System | New Taiguo WNS System | Operational & Financial Impact |
| Fuel Consumption Rate | 100% (High Baseline) | 82% | 18% Direct Fuel Savings: Cuts natural gas bills by thousands of USD monthly. |
| Steam Pressure Stability | ±0.15 MPa (Volatile) | ±0.03 MPa | Flawless Pressing Quality: Eliminates fabric water stains and processing defects. |
| Flue Gas Exhaust Temp. | 240°C – 260°C | 85°C | Massive Heat Recovery: Captures wasted energy to preheat boiler feedwater. |
| Unexpected Downtime | 3–5 Times per Month | Near Zero | Maximized Production Capacity: No more broken schedules due to refractory repairs. |
| Annual Maintenance Cost | High Regular Repair Costs | Low Scheduled Care | Lower Total Cost of Ownership: Simple automated blowdown and cleaning. |
Project Engineering Gallery For WNS Gas Steam Boiler for Garment Factory in Indonesia
Discover the real-world delivery process of Taiguo Boiler in Bandung, Indonesia. Every stage reflects our strict factory standards and global engineering capabilities.
- Manufacturing Excellence – Advanced X-ray non-destructive welding inspection of the WNS boiler shell at our manufacturing facility.
- Export Delivery – Secure heavy-duty sea freight packaging and container loading process for international transit.
- On-Site Positioning – Taiguo technical team positioning the 2-ton steam boiler and integrating local industrial pipelines.
- System Commissioning – Final thermal performance testing and automated PLC control system calibration by our engineers.
- Operational Success – The completed, clean WNS steam boiler system running smoothly at the Indonesian garment production hub.
Deep-Dive Technical Resources Of WNS Gas Steam Boiler for Garment Factory in Indonesia
Choosing the right industrial thermal system requires rigorous research. Based on this successful Indonesian garment factory project, the following resources will assist your engineering team in making an informed decision:
- Technical Specifications: Review the full pressure, capacity, and burner modulation curves on our WNS Series Gas-Fired Steam Boilers product page.
- Industry Application: Explore how we customize steam dryness and heat recovery layouts within our Textile & Garment Industry Boiler Solutions center.
- On-Site Execution: Learn more about our overseas turnkey capabilities, hydrostatic testing, and welding standards via our Industrial Boiler Installation Services portal.
- Regional Footprint: Discover further case studies, localized maintenance support, and client testimonials at our Indonesia Industrial Boiler Market .
FAQ
Why is a WNS steam boiler suitable for garment and apparel factories?
Garment manufacturing demands highly stable, ultra-dry steam for fabric ironing, garment pressing, and fabric setting. The WNS series features an enlarged internal steam room and built-in steam-water separators. This setup ensures superior steam quality and guards against fabric water stains.
What fuel options can the Taiguo WNS boiler series accommodate?
The WNS series features a highly versatile multi-fuel combustion chamber design. It can operate efficiently on pipeline natural gas (LNG), liquefied petroleum gas (LPG), light diesel oil, heavy oil, and compressed biogas.
How much fuel can a factory save by upgrading to a wet-back boiler with a condenser?
Most factories achieve a 10% to 20% drop in fuel bills. The exact savings depend on your old exhaust temperatures. Adding an integrated condenser recovers heat that would otherwise be lost up the chimney.
Does Taiguo provide complete overseas installation and commissioning support?
Yes, absolutely. We do not just ship equipment. Our dedicated overseas engineering division dispatches technicians worldwide to handle foundation verification, mechanical installation, pipeline integration, pressure testing, and local operator training.
Ready to Optimize Your Factory Thermal Efficiency?
Whether you need a high-dryness WNS Steam Boiler for Beverage Plant in Southeast Asia or a custom thermal upgrade for other food processing facilities, Taiguo Boiler’s engineering division is ready to assist. Contact our overseas department today to get your complimentary project blueprint.
- Free Thermal Load Calculations – Customized to your peak production hours.
- Custom Multi-Fuel System Design – Supporting LPG, Natural Gas, and Biogas switchover.
- Full Worldwide Installation Support – Turnkey mechanical and piping deployment.