A guide to saving money on the fourth utility – air
Magna Exterior Systems – an air leak audit case study
Magna Exterior Systems is a global automotive supplier dedicated to delivering new mobility solutions and technology. The company’s products can be found on most vehicles today and come from 348 manufacturing operations and 91 product development, engineering and sales centres in 28 countries. Magna Exterior Solutions’ UK plant in Banbury, Oxfordshire invested in a compressed air system audit, provided by Brammer Buck & Hickman.
Working with Magna Exterior Systems Brammer Buck & Hickman introduced a leak detection programme for the compressed air systems. The system was analysed using state-of-the-art ultrasonic technology and a detailed photographic report on any leakage found in the system, showing the location, size and cost of each leak, was provided. The customer’s maintenance crew then took over to address the leaks using the report as a road map.
“Our technicians went around the plant using these reports and signed each off as they completed the work,” said Paul Howard, energy improvement coordinator at Magna Exteriors Systems. “What’s more, we did the same six months later – and every six months from then – and audited the results so we have proof of the success of this approach. It has really improved our energy efficiency. Air is one of the most expensive forms of energy. It’s free to breathe but is very expensive to compress and pressurise.”
At Magna Exterior Systems, the audit resulted in £130,000 savings over three years. The company has gone from running three compressors full time to two, with the third for back-up. They are now using just two thirds of the energy and have reduced their servicing costs.
There are further benefits to be had. “Another useful aspect to this service is the safety data provided,” said Howard. “Compressed air is potentially very dangerous; it can damage equipment and cause serious injury. Knowing where the potential risks are is important and Brammer Buck & Hickman were able to recommend and provide suitable equipment to address any such issues.”
Up to 30% of a compressor’s output is lost through air leaks – a significant source of wasted energy and money. Air leak audits are a low cost, quick means of identifying leaks, putting you in a position to fix them.
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