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Elgi Equipments, one of the world's leading air compressor manufacturers, today, unveiled the Demand=Match system, a breakthrough innovation that transforms how fixed-speed compressors operate under fluctuating demand. This intelligent technology automatically adjusts compressor delivery to real-time plant requirements by smartly recirculating airflow inside the compressor, ensuring delivery always equals demand. The result: VFD-like energy savings with the simplicity and robustness of fixed-speed machines.

“Compressed air is the fourth utility in every factory, yet demand is never constant. Most factories rely on fixed-speed compressors that continue to deliver constant output even when demand drops. ELGi’s Demand=Match system brings dynamic intelligence to these machines, automatically adjusting delivery to real-time demand, helping customers save energy, reduce wear, and improve uptime without heavy capital investment” Dr Jairam Varadaraj, Managing Director, Elgi Equipments Limited.

The problem: Constant Output Vs Varying Demand

In most plants, air demand fluctuates minute by minute and shift by shift as the demand at the point of use changes constantly. Fixed-speed compressors respond to these fluctuations by cycling between cut-in and cut-out pressure bands, leading to:

• energy losses

• pressure overshoots

• frequent cycling and stress critical components

These inefficiencies increase operating costs and reduce equipment life.

The solution: Demand=Match System

ELGi’s Demand=Match technology is a breakthrough system that automatically adjusts compressor delivery to match plant demand. It works by smartly recirculating airflow inside the compressor, ensuring delivery always equals demand. This eliminates unnecessary cycling of the machine and maintains stable pressure even under fluctuating demand.

Key customer benefits

• Energy savings: Up to 17% energy reduction in typical operating profiles (field test results confirm with Product/Testing).

• Improved reliability: Fewer cut-in and cut-out cycles reduce mechanical stress and component wear.

• Cost efficiency: Capital-light implementation ensures equipment stays lifetime young.

• Sustainability: Lower energy use translates directly to reduced CO₂ emissions.

• Extended Warranty: Available on EG and EQ series - up to 10 years airend warranty on EG, 5 years on EQ 

“The system continuously monitors pressure and modulates airflow through smart recirculation. It delivers exactly what the plant needs - no more, no less, ensuring smoother operation and lower energy use.” - Dr. K. Venu Madhav, Executive President - Product Excellence & Innovation, Elgi Equipments Limited.

This launch supports ELGi’s long-term business strategy to deliver differentiated, value-driven solutions that help customers lower the total cost of ownership. By making efficiency more affordable and simpler to adopt, ELGi aims to accelerate adoption across industries, including textiles, automotive, pharmaceuticals, food & beverage, electronics, and general engineering.

The ELGi Demand=Match is available now in India as factory-fit on EG and EQ series compressors. Regional availability, pricing, and retrofit compatibility details are available from local ELGi representatives.