Atlas Copco saves energy at printing plant

25 February, 2016

When Polestar was confronted with the need to make major repairs to one of its three existing fixed speed vacuum pumps at its £100 million purpose-built Sheffield Gravure plant − a production site that has received environmental awards for its green credentials − it made sense to re-assess their combined operation to establish the potential savings that could be made by installing a more energy-efficient replacement.

Recognising the clear synergies between compressed air and vacuum in the field of air movement, it was a logical move by Polestar Sheffield to seek the recommendations of Halifax-based Pennine Pneumatic Services (PPS) for the optimum solution to their vacuum needs. Atlas Copco Compressors’ premier distributor in Yorkshire, PPS has been a long term supplier of compressed air systems, both fixed speed and VSD-driven, pipework and maintenance services to the company. As a result, a GHS900 VSD+, one of Atlas Copco's new generation of intelligent, oil-sealed, plug-and-play rotary screw vacuum pumps, was installed on a trial basis to show how it could deliver peak performance at the required operating pressure, and help achieve substantial energy savings.

Of the three existing units, the two smaller fixed speed vacuum pumps previously used by Polestar Sheffield were running at approximately 20kW an hour (one rated at 11 kW and the other at 9.7kW combined). The single GHS VSD+ vacuum pump that replaced them is a 15kW unit, which operates at approximately 20 per cent load, equating to just 4kW. Based on an operation of 8,000 hours per annum, the estimated savings are expected to exceed £10,000 (16KW x £0.08 x 8000 hours).

Harnessing advanced technology

While the gravure process is traditionally employed for long print runs, the latest engraving technology allows for short-run work with significant paper usage savings. Polestar’s elite printing site produces around 2.5 million high-quality catalogues, magazines, brochures and supplements every 24 hours.

A vacuum system plays an essential role within the transfer of work from the presses to the print finishing and bindery operations. In addition to its modern rotary gravure printing facilities, Polestar’s £34 million investment has included a purpose-built web offset 96- and 64-page size press installation together with multiple stitching stations.

Simon Robinson, engineering manager at Polestar Sheffield, said: “We pride ourselves on using the latest technology and continually look at ways to save energy which is why it made absolute sense to accept PPS’ recommendation to trial a variable speed drive rotary screw vacuum pump. The Atlas Copco GSH900VSD+ has proved a resounding success and the projections are for major savings on our energy bills over the course of a year.”

www.atlascopco.co.uk/compressorsuk