Industry:
Food & beverage industry: meat production
Situation:
As part of a wider site project, PPS were asked to come in and advise on the energy recovery options available for the current compressed air equipment.
Task:
Starting with a full compressed air visual survey, PPS found that the current air compressors were reaching the end of their lifecycle. This meant they were inefficient, unreliable and unable to be fitted with energy recovery equipment. The site was vulnerable to failure.
The next step was a comprehensive energy audit to understand the current compressed air energy usage as well as the pressure and flow required to efficiently run the site. With this data the PPS team were able to simulate how a new energy efficient system would work. The proposed system was estimated to be able to reduce energy consumption by 23%.
Other benefits of the proposed system included reducing the number of compressors on site from five to two and being able to provide full duty-standby for the site, increasing the reliability of the system. It would also continue to supply air to ISO8573.1, class 1.2.1 food quality air, in line with BCAS requirements.
Action:
Following acceptance of the proposal, PPS carried out a full installation. Before disconnecting the old system, hire equipment was connected to maintain full production throughout the install, ensuring zero downtime. Once up and running, the PPS team were able to do the full installation.
As part of the installation, PPS redesigned the plant room for ease of use for maintenance, this included installing bypasses on the pipework where needed so filtration can be serviced without affecting production. They also manufactured and installed the bespoke ducting. The ductwork moves the hot exhaust air from the new compressors out of the plant room, ensuring an optimal operating ambient temperature.
The new system is fully focused on energy efficiency. One variable speed drive air compressor is capable of meeting the full site demand and has heat recovery built into it. The system also uses dryers that are zero purge, which are more energy efficient as they use an electric heater rather than compressed air to regenerate.
An Atlas Copco Equaliser Pro 4 Controller runs the duty/standby system and efficiently equalises the run hours on both compressors, it also ensures the compressors work within a stable pressure band. The added benefit of the controller is full remote monitoring.
On completion of the installation PPS carried out commissioning and a full system handover, plus training for the onsite engineers.
The food manufacturer has ongoing support from PPS through a full warranty and maintenance package.
Results:
Energy and cost saving
Following the install of the new compressed air system, PPS conducted another energy audit to verify the savings made…
Heat recovery
Heat recovery is now built into the compressors, once this is activated within the wider heat recovery project, it will save the site a further £22,692 on their energy bill.
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.
Control
The controller adds to the increased reliability of the system by distributing the load equally between the duty and standby compressor, equalising the wear. This means both machines can be maintained on a single visit from a service engineer. A further benefit of the controller is the easy access to data monitoring and trend analysis.
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.
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.
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.