Project Overview
In 2025, a mid-sized textile factory in Tashkent, Uzbekistan, upgraded its aging steam boiler system to improve production efficiency and reduce energy costs. The factory faced challenges in maintaining consistent steam quality and reliable production schedules. After assessing multiple options, the factory chose to install a 4 Ton/Hour (TPH) Gas Fired Steam Boiler with advanced features to enhance operational efficiency and reduce overhead costs.
Client Requirements
1. Reliable Steam Supply
The factory required a continuous steam supply to meet the high demands of its dyeing, washing, and finishing processes, which operate 18-22 hours a day.
2. Energy Efficiency
The existing system was inefficient and costly to maintain. The new boiler needed to be energy-efficient to reduce operating costs while maintaining consistent steam output.
3. Compact Design & Space Efficiency
With a limited space for the boiler room, the factory needed a compact boiler solution that fit into their existing infrastructure without extensive modifications.
4. Ease of Operation
The factory staff had limited experience with complex boiler systems, so the boiler had to be automated and easy to operate.
Solution: 4 Ton Gas Fired Steam Boiler
Boiler Specifications
| Feature | Specification |
|---|---|
| Boiler Type | Gas Fired Steam Boiler |
| Capacity | 4 Tons per Hour (TPH) |
| Pressure | 10 bar (Customizable) |
| Fuel | Natural Gas |
| Efficiency | ≥ 90% |
| Control | Fully Automatic PLC Control |
| Safety Features | Flame failure protection, automatic shutdown, overpressure valves |
Additional Features:
- Compact footprint ideal for limited space
- Low NOx emissions for cleaner air
- Optional remote monitoring and troubleshooting support
Installation & Commissioning
Step 1: Site Preparation
- Foundation and grouting work completed to accommodate boiler weight and vibration isolation.
- All fuel and steam piping routes were mapped and pre-tested.
Step 2: Delivery & Assembly
- The boiler and auxiliary components were delivered to Tashkent via local transportation.
- On-site assembly was completed in 3 days, minimizing factory downtime.
Step 3: Testing & Commissioning
- The boiler went through a dry run and full pressure testing.
- Safety features were rigorously tested to ensure compliance with local regulations.
- Factory staff underwent training on basic boiler operation and emergency procedures.
Result: The installation was ahead of schedule, with minimal operational downtime, and the system was fully operational within one week.
Project Outcome & Performance
Key Results
| Metric | Result |
|---|---|
| Steam Supply Stability | 24/7 reliable operation |
| Energy Efficiency | Fuel savings of 15–20% compared to the old system |
| Production Quality | Improved dyeing consistency and fabric quality |
| Operator Satisfaction | Easy operation with minimal supervision |
| Return on Investment (ROI) | Expected within 2.5 years |
ROI Breakdown:
- Initial Investment (Boiler + Installation): $65,000
- Annual Fuel Savings (compared to old system): $12,000
- Maintenance Savings: $3,000 annually
- Total Estimated ROI Period: 2.5 years
Client Feedback
“The installation of the 4 Ton gas steam boiler was a game-changer for our factory. The steam supply is more reliable, the energy costs have significantly decreased, and the installation team was fantastic. We are already seeing a positive return on our investment and are looking forward to further expansions.”
Why This Case Study Matters for Textile Factories in Uzbekistan
1. Perfect Fit for Mid-Sized Factories
This 4 TPH gas-fired steam boiler is ideal for medium-scale textile mills in Uzbekistan, offering a balance of performance, energy efficiency, and affordability.
2. Focus on Efficiency & Long-Term Savings
By improving energy efficiency by 15–20%, this system will pay for itself in less than 3 years, making it a financially sound choice for factory owners.
3. Local Expertise and Professional Installation
The project emphasizes the importance of selecting local suppliers and professional installation teams to ensure smooth operations and quick commissioning with minimal disruption.
Detailed Cost Analysis: Gas Steam Boiler in Uzbekistan
Gas Steam Boiler Price Range in Uzbekistan
| Boiler Capacity | Estimated Price Range (USD) | Application |
|---|---|---|
| 1 TPH | $20,000 – $30,000 | Small textile mills, workshops |
| 2 TPH | $30,000 – $55,000 | Medium textile mills, laundries |
| 4 TPH | $60,000 – $100,000 | Larger textile factories |
| 6–10 TPH | $100,000 – $200,000 | Large-scale textile production |
| 20 TPH | $250,000 – $500,000+ | Industrial-scale plants |
Installation & Maintenance Costs:
- Installation Costs: Typically 10–15% of the boiler price.
- Annual Maintenance Costs: Around $2,000–$5,000 depending on boiler size and usage.
Project Takeaways
1. Accurate Sizing is Key
Correctly sizing the boiler prevents overinvestment in unnecessary capacity and ensures optimal fuel efficiency and reliable performance. For medium-sized textile factories, a 4 TPH boiler offers the best balance.
2. Long-Term Energy Savings
This project highlights how a gas-fired steam boiler with high efficiency can deliver substantial savings on fuel costs, with an ROI within 2–3 years.
3. Easy-to-Operate Systems
Automation and safety features make these boilers user-friendly, reducing the need for skilled operators and minimizing human error.
Conclusion: Gas Steam Boilers for Textile Factories in Uzbekistan
Gas-fired steam boilers offer textile factories in Uzbekistan a cost-effective, reliable, and energy-efficient solution to meet their production needs. The 4 TPH gas steam boiler installed in Tashkent provides significant savings, improved operational stability, and a rapid return on investment.
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