Situation
A leading carpet manufacturer based in the North of England approached PPS as part of its drive to improve energy efficiency and reduce operating costs. With sustainability and efficiency becoming increasingly important across the manufacturing sector, the company had started reviewing various areas of its production process to pinpoint energy losses.
During the investigation, it became evident that the compressed air system was underperforming. The customer suspected a significant number of air leaks throughout the system, especially in the ageing pipework. Not only could they hear the leaks, but they were also concerned about potential safety issues and wasted energy.
Task
The primary objective was to identify and address all existing leaks within the system.
PPS carried out a comprehensive compressed air leak detection survey. Using advanced ultrasonic detection equipment, our engineers thoroughly assessed the system, tagging each leak on-site and compiling a detailed report outlining the location, severity, and potential cost implications of every leak.
In total, 40 individual leaks were identified across the facility. The largest was recorded at a noise level of 89 dB, a clear indication of substantial air loss and a potential health and safety concern for nearby workers due to excessive noise exposure.
Action
Following the survey, PPS engineers returned to the site to carry out the necessary repairs. Over a two-day period, our team worked efficiently to fix all identified leaks without causing any disruption to the customer’s production schedule.
Results
- Significant cost savings: By eliminating the 40 air leaks, the manufacturer is now saving over £36,000 per year on compressed air energy costs. The savings are based on a price of £0.12/kWh.
- Reduced waste: All compressed air generated is now being used efficiently in the carpet weaving process, rather than being lost through leaks.
- Safer working environment: The loudest leak, previously registering at 89 dB, has been fixed, greatly reducing noise levels and improving onsite health and safety conditions.
- Increased system reliability: With fewer leaks, the compressed air system operates under less strain, leading to improved performance and lower maintenance requirements.
- Lower carbon footprint: The reduction in energy consumption contributes directly to the company’s sustainability goals and supports a greener production process.