At a Midwest window manufacturing plant, the cooling process for the plastic frame pieces, after leaving the extruder, was critical to process productivity and quality. Too much cooling air (or not enough cooling air) would generate scrap and rejected product. The plants’ 17 extruders and 55 separate blow-offs in these lines had similar cooling stations at the cooling boxes. They consisted of about three hoses at each exit frame angled down to the extruded piece moving past it. The compressed air flow was controlled by a manual control valve set by an operator. The operator used his experience to control the flow delivered and thereby control the product quality.
A basic element in the Compressed Air Challenge® (CAC) philosophy is that compressed air system optimization should be addressed using the “Systems Approach”. This method recognizes that improving and maintaining peak compressed air system performance requires addressing both the supply and the demand sides of a system and understanding how the two interact. “The road to energy efficiency involves more than just fixing the leaks,” says Ross Orr, an experienced auditor with Scales Industrial Technologies and a certified CAC instructor.
This factory currently spends $735,757 annually on the electricity required to operate the compressed air system at its plant. The group of projects recommended in the system assessment will reduce these energy costs by an estimated $364,211 (49% of current use). Estimated costs for completing the recommended projects total $435,800. This figure represents a simple payback period of 14.4 months.
Compressed air leaks - every system has them. Is a leak identification and control program economically rewarding and/or necessary? Upper management sometimes doesn’t recognize the true cost of not repairing air leaks. Knowing the high cost of compressed air, why wouldn’t every facility with a compressed air piping system implement a continuous leak identification and repair program?
The snack food facility is running with two normally separated compressed air production systems: the main plant system and the nitrogen system.
This commercial printing facility is located in the Northeastern part of the U.S. Like most facilities, the plant has seen many changes over the years.
Sustainability at RRD starts with a philosophy. It is then executed through a global policy and objectives. RRD’s philosophy does not see sustainability as making a choice between being cost-effective and improving environmental impacts. On the contrary, sustainability represents integrating these two factors. This philosophy guides our sustainability objectives and strategies.
This article will focus on a compressed air system assessment done at a printing facility in Canada. The energy costs at the time, in Manitoba, were $0.025 per kWh and the installation was of just 65 horsepower of air compressors.
Over the last several decades, Air Power USA has reviewed many various types of plastic injection molding operations throughout the U.S.
A recent comparative vacuum technology study performed by Dr. Kingman Yee, as part of a Chrysler Summer Intern Professors Program, found that air consumption could be reduced by 98% when equipping a robot’s end-of-arm tooling with COAXÆ technology and a Vacustat™ check valve.
This stamping plant is a 2.5 million-square-foot facility with over two thousand employees. At the time of the assessment, the plant was processing approximately 1,600 tons of steel per day into automotive vehicle components and parts such as body parts.