Industries

A Canadian fiberglass plant has completed a lengthy compressed air improvement journey and achieved significant efficiency gains by applying “the systems approach.” Along the way, the company ran across many frustrating problems, the solutions to which were only determined after the entire system was monitored holistically using data loggers. The overall compressed air audit led to a reduction in energy usage of 48 percent, yielding savings worth \$17,500 per year. The project also qualified for a large utility incentive of \$32,000 with a calculated payback of 4.4 years.

Sometime in mid-2015, I received a call from a project engineer at a major plastics firm. He had a troubling issue with one of his PET bottle plants. The bottom line was this: They could not run all five high production blow-molding machines at one time—even though they were able to do so 18 months previously.

Plastic injection molding is a common process in manufacturing, and it can be used to produce just about anything. To create a part, molten plastic is injected into a hollow mold, where it is formed and cooled before being ejected from the cavity. Plastic injection molders make a seemingly limitless range of products, from fishing tackle boxes and kayak paddles to tooth brushes and miniscule medical devices.

Any modern food manufacturing facility employs compressed air extensively in the plant. As common as it is, the potential hazards associated with this powerful utility are not obvious and apparent. Food hygiene legislation to protect the consumer places the duty of care on the food manufacturer. For this reason, many companies often devise their own internal air quality standards based upon what they think or have been told are “best practices.” This is no wonder, as the published collections of Good Manufacturing Practices (GMPs) that relate to compressed air are nebulous and difficult to wade through.

Air-operated double diaphragm (AODD) pumps are common to many manufacturing facilities. As estimated by veteran compressed air auditor Hank van Ormer of Air Power USA, approximately 85 to 90 percent of plants in the United States have AODD pumps. They are used for all kinds of liquid transfer applications, like those found in chemical manufacturing, wastewater removal, and pumping viscous food products.

One of the statements made in the Compressed Air Challenge’s Fundamentals of Compressed Air Systems seminar is that improvements can always be made to every compressed air system, including new ones. The statement definitely applies to a Canadian pork processing facility built a few years ago. This article is based on a compressed air audit performed two years into the life of a brand new plant. The audit found numerous problems and made recommendations that helped reduce plant compressed air operating costs by 60 percent. 

ISO 22000 is a food and beverage (F&B) specific derivative of ISO 9001, a family of standards from the International Organization for Standardization that details the requirements of a quality management system. It is a quality certification that can be applied to any organization in the food chain — from packaging machine manufacturers to the actual food processing facilities.

A modern dairy without compressed air is nowadays no longer imaginable, and it is used primarily for driving control units and machinery. Approximately 60 percent of the compressed air generated is used for packaging lines. However, compressed air is one of the most expensive energy sources in dairies. Even in carefully maintained compressed air systems, about 20 percent of the generated energy is lost through leaks. In particular, vacuum leakages in separators result in high energy losses. A small leak can cost up to several thousands of Euros a year.

Compressed air is used in more than 70 percent of all manufacturing activities, ranging from highly critical applications that may impact product quality to general “shop” uses. When compressed air is used in the production of pharmaceuticals, food, beverages, medical devices, and other products, there seems to be confusion on what testing needs to be performed.

Ahresty Wilmington Corporation (AWC) was founded in 1988 and is located in Wilmington, Ohio. Currently AWC employs over 900 people with sales totaling \$192 million. They have grown steadily, all while continuously improving and staying on the leading edge of technology. AWC is a tier-1 automotive supplier servicing their entire customer base in the United States. AWC has established an efficient and integrated production system that incorporates die-casting, finishing, machining, and assembly operation using just-in-time production methods to provide its customers with quality products at a competitive price.