Industrial Utility Efficiency    

Industries

A small Australian company, Basil V.R. Greatrex (BVRG), is shaking up the compressed air industry in Australia. While other companies focus on the sale of more and bigger compressed air production equipment, BVRG is helping customers reduce their compressed air system size and lower system flow by attacking waste, inappropriate use, and at the same time improving air quality.

Auto

This northeastern U.S. automotive manufacturing facility spends $269,046 annually on energy to operate their compressed air system. This figure will increase as electric rates are raised from their current average of .019 cents per kWh. The set of projects, in this system assessment, reduce these energy costs by $110,166 or forty percent. Reliability of compressed air quality, however, is the main concern in this plant and the primary focus of this system assessment.

Bulk

The Lafarge Cement Distribution terminal located in Winnipeg, Canada has significantly reduced the site electrical demand and energy charges by changing the way they transport their cement.  Two new low-pressure rotary screw air compressors have replaced two large high-pressure air compressors that previously powered their dense phase transport system.  The resulting power reduction has saved the company 46 percent in transport operating costs.

Food

A small pulse crop and seed processing facility located in Canada has upgraded their facility compressed air system to accommodate the expansion of their production capacity.  While completing this project the facility has learned some valuable lessons about sizing and maintaining lubricated screw air compressors and compressed air drying equipment.

Medical

In the U.S. as an example, the NFPA has taken the view that if your compressor draws in good clean ambient air, the air stays clean through the compressor, is then dried and filtered, when you deliver it to the patient it will be entirely satisfactory. After all, when you went into the hospital that’s what you were breathing and when you leave you will breathe it again!

Metals

The company specializes in fabrication of precision assembled customized parts for OEM’s and system integrators. Since 1997 the company has steadily grown in size and capacity as the demand for its high quality fabrications has increased.  Through the years, many new CNC machines, laser cutters and powder coat painting operations have been added, but with all the expansion the facility has amazingly kept the plant compressed air consumption low. This has been achieved by following excellent “best practice” compressed air efficiency principles and by keeping watch on system waste.

Paper

Rockline Industries is one of the largest global producers of consumer products, specializing in wet wipes and coffee filters. The company contacted the Arkansas Industrial Energy Clearinghouse after identifying that the compressed air system in their Springdale, Arkansas facility was a potential source of significant savings. Experts from the Clearinghouse then began working with Rockline Industries, representatives of the electric utility, and a local compressed air vendor to perform a complete evaluation of the system.

Pharmaceutical

Compressed Air Best Practices® Magazine interviewed Mr. Warwick Rampley, the National Sales Manager for Sydney (Australia) based, Basil V.R. Greatrex Pty Ltd. It’s not every day one is asked to deliver a system able to provide both a reliable compressed air dew point of -80°C (-112°F) and high purity nitrogen.  We work with some excellent technology suppliers and have engineered a rather interesting system.  Although our firm was founded in 1919, this application is one of the most demanding we’ve encountered. Basil V.R. Greatrex is a unique company as we focus only on compressed air measurement, compressed air quality and compressed air efficiency.

Plastics

A plastic product manufacturer spends an estimated $245,000 annually on electricity to operate the air compressors in a compressed air system at its plant located in a midwestern U.S. state.  The main manufacturing process is plastic extruding. The current average electric rate, at this plant, is 7 cents per kWh. The compressed air system operates 8,760 hours per year and the load profile of this system is relatively stable during all shifts.

Power

A newly constructed ethanol plant experienced control gap issues shortly after comissioning.  This article discusses the cause of the issue and how the problem was solved.

Printing

The Trinity Mirror Group print works on Oldham is one of the UK’s largest newspaper printers. The nine presses in the facility produce around 1million papers every day, including the Independent, the Daily Mirror and a range of local, regional and sports titles. Printing on this scale does not come cheap in energy terms, however. The plant’s annual electricity bill is in the order of £1.5millon. With energy prices on the rise, and a strong desire to improve environmental performance and reduce its carbon footprint, the plant’s management has recently embarked on a project to cut energy use substantially.

Transit

In aerospace manufacturing, tiny details matter most. For instance, if proper torque is not applied to the screws and bolts fastening an aircraft fuselage, catastrophic failures can result. Compressed air is used to power the tools needed to apply that torque, making the compressed air system a critical part of the facility, though it largely stays behind the scene.

Wastewater

A replacement strategy for air compressors and blowers integrated into a system-level approach towards energy efficiency can deliver significant energy savings and optimize equipment performance. At the Victor Valley Wastewater Reclamation Authority, a blower replacement project yielded annual energy savings of more than 928,000 kWh and $98,000 in energy costs, while improving the reliability of its secondary treatment process. In addition, the agency qualified for important incentives from its electric utility — significantly improving the project economics and resulting in a 2.94-year payback.
Compressed Air Best Practices® Magazine interviewed Michael Jones, Corporate Energy Team Leader, from Intertape Polymer Group (IPG). Intertape Polymer Group (IPG) is a manufacturer of tapes, films, woven fabrics, and complementary packaging systems for industrial and consumer use. The company operates 10 production plants and employs approximately 1,800 people. IPG has developed a robust energy management program by using ENERGY STAR energy management tools and actively participating in the ENERGY STAR partnership. IPG is receiving ENERGY STAR recognition for the growth of its energy program and leadership as a medium-sized manufacturer.
This is a food processing plant where processes and standards are controlled by FDA to AIB standards. Annual plant electric costs for compressed air production, as operating today, are $116,765 per year. If the electric costs of $3,323 associated with operating ancillary equipment such as dryers are included, the total electric costs for operating the air system are $120,088 per year. These estimates are based upon a blended electric rate of $0.085/kWh.
As you walk past the “sandblasting cabinet” back in the corner of the plant running alone and without the need for monitoring, does the thought of operational costs enter your mind? When it does, are you happy knowing the cabinet is automatic and does not need a full-time operator? Then, did you say to yourself, I wonder how much that abrasive media costs? How long does it last? Is this a more cost competitive alternative? Is there something that might last longer?
Compressed air is used in a number of processes in the food industry. It is used as an ingredient in whipped products such as ice cream, to slice or cut soft products and to open packagesbefore filling of product. Currently, food manufacturers are under pressure to validate the safety of all ingredients or processes for regulatory compliance, but unfortunately, there is currently no standard method to evaluate the microbial content of compressed air.
This paper mill currently spends $1,747,000 annually on energy to operate the compressed air system at their plant located in the southwestern region of the U.S. The set of projects recommended, in this system assessment, could reduce these energy costs by $369,000 or twenty-one percent (21%). Estimated costs for completing the projects total $767,900, representing a simple payback of 25 months. More importantly, these projects will improve productivity, quality and maintenance costs - many associated with poor compressed air quality.
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 $170,718 or 56% of current use.  In addition, these projects will allow the plant to have a back-up compressor and help eliminate the rental expenditure for compressor maintenance or downtime.
Nutriom sets the bar high when it comes to producing its premium quality natural powdered egg products Ova Easy® and Egg Crystals®, that are sold at outdoor retailers such as REI, and online merchants such as Amazon.com; so, when the screw conveyor in their FSIS USDA facility required regular unexpected attention, Leonardo Etcheto, Plant Manager at the Lacey, WA facility knew it was time to look for a better solution.
This is a corn mill processing cornstarch, sugar, and other byproducts. Ambient air is contaminated with extremely high levels of dust due to the manufacturing processes and material handling. Average electric rates at the plant are $0.04 / kWh. The actual plant electric cost for compressed air production is $553,630 per year.
This food & beverage plant is a large (500,000 sq ft) meat processing plant with twenty packaging lines and nine palletizers. The compressed air system is supplied from three separate rooms with seven individual lubricant-cooled, single and two-stage rotary screw compressors. The plant has four blower purge desiccant dryers designed to deliver a - 40°F pressure dewpoint.
It was the Fall of 1997 in Germany. I was just another guy working in the German compressed air industry. East Germans were still being looked down on - seven years after unification, the Euro was launching in little over a year - forcing marketing managers like me to scramble and create unified european Euro pricing strategies, European Cohesion Funds were flowing out of Germany and into the Mediterranean (not literally), and the diminutive Mercedes “Smart Car” was the cool car for space-challenged urban dwellers. With this going on, you can imagine the surprise of the compressed air industry when compressed air was featured in “Der Spiegel”, a “Newsweek-like” weekly magazine in Germany with national distribution.