Situation
A plastic recycling company with a strong focus on sustainability recently turned to PPS to help reduce its energy usage. Operating in an energy-intensive sector, the customer relies heavily on electricity to melt down plastic waste for reprocessing, with compressed air playing a critical role in the manufacturing process.
With strict carbon reduction targets to meet, the business was actively looking for ways to improve energy efficiency and reduce its environmental impact, without compromising production.
Task
PPS was called in to assess the compressed air system and identify where energy savings could be made. The initial goal was to locate and quantify any air leaks across the system and provide recommendations to help the company optimise performance and reduce waste.
Action
Using ultrasonic acoustic detection equipment, a PPS engineer carried out a full site survey. The inspection found 16 compressed air leaks, each of which was individually tagged. The customer was then provided with a detailed leak report outlining the location, estimated air loss, and potential financial savings for each issue. Following the survey, PPS supplied the necessary parts to repair all identified leaks.
Results
- Major cost savings: The company is now saving over £15,350 annually on compressed air energy costs. (The savings are based on a price of £0.12/kWh.)
- Lower carbon footprint: With reduced energy waste, the business is making better progress toward its carbon reduction goals, supporting its wider sustainability strategy.
- Increased system capacity: The site was experiencing a compressed air leakage rate of approximately 74 CFM, almost half the capacity of its 150 CFM compressor. With the leaks fixed, the system can now operate more efficiently and meet production demands more effectively.
- Improved reliability and safety: A leak-free system means less wear and tear, fewer unplanned maintenance issues, and a safer working environment for employees.