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This manufacturing facility were looking to reduce their operational costs and improve their energy efficiency.
We had to determine their current usage so that we could identify a solution that would achieve the results. Our team conducted a detailed compressed air energy audit at the time to assess the performance of their existing equipment and highlight key areas for operational improvements and cost saving.
With over 10% of industrial electricity demand used for compressing air, a simple analysis can often yield significant savings. Compressed air audits assist the engineering team in accurately calculating compressor demand to avoid oversupplying pressure, selecting the most suitable compressor and quantifying the impact of potential changes on energy usage.
With the data we accumulated, our team were able to predict an approximate energy saving of between 27% and 29% with the addition of variable speed air compressors.
We started by removing three existing fixed speed compressors and replacing them with two variable speed compressors, programmed to run in a duty/standby configuration.
The variable speed technology eliminates offload running of the compressors whilst meeting the same air demand. As the compressors only function when production requires it, the operating life is drastically increased while servicing costs and energy consumption are reduced considerably.
These air compressors are designed to meet the need for continuous 24/7 operation when required.
The twinned units and alternate operating pattern not only give 100% backup, but also equalise running hours and allow for coordinated serving.
We provide best-in-class air compressors that prioritise energy efficiency, cost saving and dependability. Since we are independent of air compressor manufacturers, we are able to find the most suitable system on the market from our list of trusted suppliers.
Not only that, but our team can provide advice on applicable legislation, relevant standards and industry best practice.
Across our suppliers and the systems available to us, we can provide solutions suitable for automotive and aerospace, dairy, food and drink, manufacturing and pharmaceutical facilities.
Our customised packages also give you access to individual compressor servicing and comprehensive support across multiple sites if necessary.
Plus, we have a 24/7 service portal that gives you access to all the jobs and replacement parts used.
Click here to read more about the importance of compressor maintenance.
Get in touch and we would be happy to help.
In this instance, the actual energy saving achieved far exceeded the original prediction by 13% to 15%, reaching an impressive 42% energy saving.
Plus, the supplementary benefits of reduced noise levels and hot exhaust recovery made this a smart choice.
Here’s what the facility’s Engineering Manager had to say:
“I am thrilled with the results of the installation of the new compressor system.
The 42% energy savings achieved have far exceeded my expectations.”
Find out more about air compressors or get in touch for more details.
You can talk to one of our team today by calling us, or if you prefer, get in touch online.
