The first step towards compressed air efficiency takes just 10 minutes

24 October, 2018

Energy audits

What also shouldn’t be overlooked is the vital role system energy audits can play in identifying opportunities to improve health and safety. For instance, incorrectly specified compressed air equipment, air leaks and poorly sized pipework with long runs, excessive bends and fittings can all pose a risk. Accordingly, responsible compressor systems manufacturers and suppliers should seek to identify these potential hazards during the audit process and provide recommendations on how to address them.

This audit-led approach is backed up by a number of real-word case studies. For instance, one UK-based company to have recently benefited is Buxton Press. The magazine printing company began the process by participating in an iiTrak system energy audit that indicated the level of air leakage from its existing pipework was high. As a result, the company opted to install a new ring main and 75 kW VSD compressor with ancillaries. This is calculated to result in an annual carbon reduction of approximately 48 tonnes of CO2, along with close to £7500 per annum savings in compressed air energy costs.

In another recent example, Kingsmoor Packaging, the manufacturer of bespoke thermoformed plastic packaging for the food industry, was able to increase both its production capacity and energy efficiency. It achieved this after initially agreeing to an energy audit to check the load cycle profile for each compressor within its system. The goal of this exercise was to create a representation of the air and energy being used during a typical production week.

The resulting data was then used to extrapolate an annual use of compressed air, the energy used and its cost. The outcomes of the assessment ultimately led to Kingsmoor Packaging downsizing from a 110 kW to a 90 kW VSD compressor, which reduced the operating pressure of the system and is saving the company in the region of £47,000 per year.

 Little interruption

Despite these types of savings now being widely achievable through the latest advances in VSD compressed air technology, some companies continue to be put off by the perception that the crucial installation stage could be disruptive to day-to-day operations. In reality, when it is handled by a reputable OEM or one of its authorised distributors the process will have been meticulously planned to have as little interruption as possible. For instance, where feasible, the installers will utilise existing back-up compressors or the ones being replaced, to ensure there is no loss of production.

Simply installing the compressor is not enough however. Responsible OEMs and distributors should offer 24/7 support in the weeks immediately following installation, to ensure everything runs smoothly, and then encourage the end user to adopt a service contract that will ensure they have peace of mind throughout the total lifecycle of their system.