Situation:
The leading cake manufacturer contacted Pennine Pneumatic Services Ltd (PPS) as their compressed air installation was ageing and inefficient. Their manufacturing site was powered by two fixed speed compressors and one variable speed drive compressor, these had become prone to breakdowns and parts were becoming increasingly expensive and difficult to source.
Task:
PPS carried out a full energy audit of the compressed air system, including site survey. This is a non-intrusive way to understand the overall air demand and usage profile of the site. Using the customers energy tariff we were able to give them a realistic estimate of the energy cost of running their current equipment. Using the data, PPS then ran a simulation to show how their site would run with an upgrade to their compressed air system.
Action:
The PPS simulation showed they could save 19% on their annual compressed air energy bill by upgrading from their current set up of two fixed speed and one variable speed air compressors, to just one variable speed drive air compressor capable of running their whole site.
Additionally, the compressor room was cramped. The ageing equipment took up a large amount of space, this meant awkward access for routine services and poor ventilation around each compressor, further compromising performance. There was no pipework to allow for bypassing receivers or in-line filters, so any routine servicing meant de-pressurizing the entire system, resulting in costly downtime on a routine basis.
PPS installed a full duty/standby compressed air system with an optimised compressor room. Air receivers can be easily bypassed for annual insurance inspections and in-line filters can be isolated for routine services – without affecting 24/7 production in the plant. This also included bespoke ducting manufactured by PPS to move the hot exhaust air from the new compressors out of the plant room, ensuring an optimal operating ambient temperature.
During the installation the manufacturing site was kept running by using an air compressor from the PPS hire fleet. The full project was planned carefully with the customer to avoid unnecessary downtime. At commissioning the two air compressors were set to rotate weekly between duty and standby to equalise run hours.
Following completion, the manufacturer took out a seven-year Guardian service plan with PPS, giving them full warranty, complete peace of mind and fixed servicing costs for the duration of the agreement. This worked out to be a more cost-effective plan than their previous set up.
Results:
Energy and cost saving
Space saving
The vertical drive arrangement of the new compressors has opened up several square meters of floorspace, making for a very clean installation with ample room for adequate air flow and to conduct routine services.
Reliability
Atlas Copco air compressors are renowned for their reliability, but the new compressed air system also has a full duty/standby set up to allow servicing whilst maintaining full production.
By taking out a service plan, they also further protect the reliability of their system. On average, customers with a compressor service plan in place enjoy 3.5% more production uptime than those without one.
Optimised compressor room
Air receivers can be easily bypassed for annual insurance inspections and in-line filters can be isolated for routine services – without affecting 24/7 production in the plant.
Fixed costs
By taking out a 7 year service plan they have been able to fix their servicing costs, helping them avoid price rises and making budgeting easier. This plan is more cost-effective than their previous set up.
Remote monitoring
The customer can now use the Atlas Copco SmartLink system, which continually monitors the operation and condition of each compressor. They receive monthly usage reports and can receive alerts in case either unit should develop a warning or shutdown– this enables the customer to be pro-active, rather than reactive to their compressed air system.
Complete turnkey installation
The entire project from energy auditing to specification, to install, ducting and servicing was carried out by in-house PPS teams. This made the management of the project easier without needing a host of sub-contractors.