Zephyr Textiles, a prominent name in Pakistan’s textile industry, continues to lead with innovation and sustainability.

In 2020, one of the three generators in Zephyr’s 5 MW CHP powerhouse completed its lifecycle. This powerhouse not only generates electricity but also produces approximately 3 tons of steam per hour to support factory operations. To maintain uninterrupted performance and achieve maximum energy efficiency, Zephyr Textiles sought a reliable replacement solution.

Energy Solutions Private Limited, the exclusive partner for Cummins gas products in Pakistan, supplied a 1.1 MW Cummins QSK60 gas generator (Model C1160N5C). The generator was seamlessly integrated with Zephyr’s existing control systems and CHP infrastructure.

Over the following two years, the Cummins generator underwent rigorous reliability testing and consistently demonstrated exceptional performance, including no derating during peak summer seasons, high torque-bearing capability, zero tripping over 16,000 operating hours at an average load of 95%, outstanding aftermarket support, and excellent overall generator efficiency.

Encouraged by these results, Zephyr Textiles proceeded to replace a second unit with the advanced Cummins HSK78 C2000N5CD 2 MWe gas generator. The Cummins HSK78 is the only 2 MW-class engine that offers the best of both worlds, delivering best-in-class electrical efficiency, exceptional torque-bearing capability, and the ability to operate on a wide range of fuel gases without derating, even at ambient temperatures up to 55°C.

Energy Solutions Private Limited successfully commissioned this new unit in just three days. Today, Zephyr’s powerhouse operates efficiently on two Cummins generators, meeting all power requirements while retiring the older non-Cummins unit.

The HSK78 set has already surpassed 18,000 hours of reliable operation. Despite challenges such as high gas prices and low gas pressure, the Cummins generators continue to deliver unmatched reliability and performance.

This successful collaboration reflects Zephyr Textiles’ confidence in Cummins technology and ESL’s engineering expertise.