Industrial Utility Efficiency

Metals

IPS Advises Midwest Industry on Compressed Air Efficiency

By Troy Dreier, Senior Editor, Compressed Air Best Practices® Magazine

IPS supplies compressed air to a lot of machinery running outdoors, such as dust collectors and feed mills on grain elevators, as well as to other equipment in environments lower than 32°F (0°C). Temperatures that low require desiccant dryers. Hoffman helps his customers sort out their options and determine which type of desiccant dryer – heatless, heated purge, heated blower purge – is ideal for their needs.

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6 Steps Metal Fabricators Take to Reduce Compressed Air Demand

By Kirk Edwards, EXAIR Corporation

Compressed air use in the metal fabrication industry is widespread. It is used to cool, clean, convey and coat a multitude of products and improve processes across the world. In fact, it is difficult to name processes in metal fabrication where compressed air cannot be found. A few processes where compressed air is used include: annealing and pickling, slitting, rolling, welding, stamping, punching, tube making, painting, finishing, turning, drilling, milling and sawing. Many of these processes and applications continue to use inefficient devices to deliver the compressed air, and — worse yet — many companies fail to recognize the simple implementation and significant payoff of improving compressed air efficiency.
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Nissan Curbs Compressed Air to Achieve Energy Savings

By Compressed Air Best Practices® Magazine

Nissan North America operates on a massive scale. The company’s powertrain assembly plant in Decherd, Tennessee, alone encompasses 1.1 million square feet, and manufactures engines for 14 different vehicles. The facility also handles crankshaft forgings, cylinder block castings, and other machining applications. Over the course of one year, the powertrain plant churns out approximately 1.4 million engines, an equal number of crankshaft forgings, and 456,000 cylinder block castings.
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Foundry Air Compressors Out of Control

By Ron Marshall for Compressed Air Challenge®

Quite a number of worst-case compressed air scenarios have been encountered over the years but none may compare to the conditions that existed in a metal foundry somewhere in North America. For reasons you are about to discover, we will not reveal the name of this factory or its location, in order to protect the innocent from embarrassment.
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Compressed Air Supply at a Metal Machining Plant

By Don van Ormer, Air Power USA

This metal fabrication and machining facility produces high-quality precision-built products. Over the years, the plant has grown and there have been several expansions to the current location. The company currently spends \$227,043 annually on energy to operate the compressed air system. This figure will increase as electric rates are raised from their current average of 9.8 cents per kWh.
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Evaluating Operational Costs of Sandblasting Operations

By Scott van Ormer, Air Power USA

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?
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Arkansas Industrial Machinery Helps TIGG Reduce Energy Costs

By Kevin Conley, Arkansas Industrial Machinery

TIGG Corporation, a manufacturer of activated carbon adsorption vessels, custom air receivers and other steel tanks and pressure vessels, substantially reduced its energy costs after implementing equipment, labor consolidation and procedural changes resulting from a compressed air energy audit. The audit was performed at TIGG's 155,000 square feet manufacturing facility in Heber Springs, Arkansas to determine the efficiency of the existing compressed air system and to set a baseline for TIGG's participation in Entergy Arkansas’ Large C&I Custom Incentive Program.
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Precise Air Gauging in Metal Fabrication and Machining Centers

By Chris Koehn, President, Stotz USA

Air gauging relies on a law of physics that states flow and pressure are directly proportionate to clearance and react inversely to each other. As clearance increases, air flow also increases and air pressure decreases portionately. As clearance decreases, air flow also decreases and air pressure increases.
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International Wire Trims Compressed Air Costs Using the “Systems Approach”

By Tom Taranto and Ram Kondapi for the Compressed Air Challenge®

International Wire Group, Inc. (IWG) headquartered in Camden, NY is the largest bare copper wire and copper wire products manufacturer in the United States with expanding operations in Europe. Products include a broad line of copper wire configurations and gauges with a variety of electrical and conductive characteristics , which are utilized by a wide variety of customers primarily in the industrial and energy, electronics, data communications, aerospace and defense, medical electronics and devices, automotive, and consumer and appliance industries.
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Industrial Sandblasting – Where Does All the Air Go?

By Don van Ormer & Scott van Ormer, Air Power USA

“Sandblasting” is one of the oldest and most used methods of metal treatment. Various abrasive materials may be loaded manually or by a vacuum system pulling the “grit” from a storage tank. A control valve then operates with the compressed air (bypassing the vacuum pump), being forced into the tank pressurizing the receiver. When the high pressure compressed air goes out the discharge line, it pulls the appropriate amount of grit with it to effectively impinge against the targeted metal surface.
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