Industrial Utility Efficiency    


Parrheim Foods, a division of Parrish and Heimbecker, is an innovative starch, protein and fiber mill situated in Saskatoon, Saskatchewan, Canada.  The plant has improved system efficiency and reduced production problems by addressing some problems with the consumption of compressed air by their reverse pulse baghouse cleaning operations.  This effort has allowed them to turn off one of their 100 hp air compressors, saving significant electricity costs.
This article reviews portions of an audit report of a compressed air system in a food industry factory located in the U.S. Although the audit explored different supply-side options the client should consider to improve dynamic efficiency, we will focus on the demand side of the system for this article.
This brewery is a relatively large operation with nine production lines plus a keg line. There are five bottle lines and four can lines. Operations in the plant include palletizing de-palletizing, filling, packaging operations, and brewing. Annual plant electric costs for compressed air production, as operating today, are $693,161 per year.  If the electric costs of $43,016 per year associated with operating ancillary equipment such as the blower purge dryers are included, the total electric costs for operating the air system are $736,177 per year.  These estimates are based upon a blended electric rate of $0.06 /kWh.
  In an ideal world, industrial air or gas supply lines would be free of particulate, water, oil and other contaminants. In the real world, however, supply lines typically deliver some contaminants along with the air or gas they were designed to carry. Left unchecked, these contaminants will cause efficiency losses, maintenance headaches and the premature failure of pneumatic components.
This meat processing and packaging factory spent an estimated $203,640 annually on energy to operate the compressed air system at their Midwestern facility. Based on the air system operating 8,760 hours per year, the group of projects recommended below could reduce these energy costs by an estimated $107,522 or 47% of current use. In addition, these projects will decrease compressor maintenance costs. Estimated costs for completing the recommended projects total $21,900. This figure represents a simple payback period of 2 months.
Using suction cups and air-driven vacuum pumps is a preferable gripping and handling method of corrugated cardboard materials and boxes in carton-machines like case/carton erectors and rotary cartoners. Robot based applications, like palletizing and de-palletizing, are other examples where the best practice technology for gripping and handling is by suction cups and air-driven vacuum pumps.  
This facility operates one of the largest compressed air installations in industry, with 21 4000 hp process air and five 750 hp instrument air centrifugal compressors to support large-scale aerobic fermentation and related processes that require large volumes of oxygen.  
A recently completed energy efficiency improvement programme at the Britvic Beckton bottling plant has resulted in substantial energy savings and a positive impact on the company’s carbon emissions allocation.
This facility is part of a major corporation with dozens of manufacturing facilities where consumer good food products are processed and packaged for shipment to retail outlets. The factory was spending $210,000 annually on energy to operate their compressed air system. This system assessment detailed four (4) project areas where yearly energy savings totaling $100,855 could be found with an investment of $100,000.
Compressed air is a key utility supporting the food packaging and food processing industries in North America. Compressed air must be contaminant-free to ensure the protection of the food products processed in each facility. The U.K. Code of Practice for Food-Grade Air helps define three types of compressed air systems and air purification specifications required for each.
In the 1970s, the use of filtration in air quality management in pharmaceutical production, hospitals, and medical device manufacturing facilities became increasingly important and increasingly of interest to regulatory agencies. The air quality field was growing. From the air moving into and out of clean rooms to the protection of surgical environments to the expansion of the global medical drug industry, compressed air began to play a larger role—a role that continues undiminished (and, in fact, has increased substantially) today.