Industrial Utility Efficiency    

Industries

Outsourcing maintenance agreements for compressed air systems is commonplace in the food and beverage industry. The maintenance programs are often performed by air compressor distributors, who are experts in the specifics of the air compressors and compressed air systems they sell and service.

Auto

The Ford Motor Company Kentucky Truck Plant (KTP) not only manufactures upscale SUVs and pickup trucks painted in wide variety of stellar, high-quality colors and finishes –  it does so cost-effectively by conserving annual compressed air energy of approximately 9.2 GWh thanks to a major overhaul of the plant’s compressed air system.

Bulk

Reverse pulse type dust collectors often represent a challenge to compressed air energy efficiency, and sometimes throw a wrench into the works by causing huge air pressure fluctuations, high transient flows and just plain large leaks. This article discusses this type of dust collector, often installed in food processing plants, and gives some real-life examples of problematic installations. Some suggested measures are mentioned to ensure your dust collectors keep running in a trouble-free manner.

Food

Electricity and compressed air play an important role in the thermal and kinetic processes for everything from mixing and extruding the ingredients, deep-freezing to -13°F (-25°C), dipping into various chocolate coatings through to final packaging. Energy efficiency is therefore right at the top of Unilever’s list of priorities. As part of the Unilever Sustainable Living Plan, this global corporation has succeeded in saving more than $186 million in energy costs from efficiency improvements in production alone since 2008.

Medical

The air is delivered through a distribution piping system that ends with a medical air outlet within the room. Outlet requirements per room are governed by American Institute of America (AIA) Guidelines for Design and Construction of Hospitals and Healthcare Facilities. Equipment is plugged into the medical air outlet to treat the patient. Many studies have been done determining the load required for medical air compressors. The sizing can be calculated using several methods. 

Metals

Manufacturers familiar with the U.S. Environmental Protection Agency (EPA) ENERGY STAR® Energy Treasure Hunts initiative know it’s a great way to save energy and natural resources – as long as it’s done right – which is why some are turning to perhaps their best asset to achieve success: their unionized workforce.

Paper

The facility has a compressed air system consisting of four, 200-horsepower (hp) two-stage water-cooled lubricant-free reciprocating air compressors. The air compressors are controlled individually with local pressure switch controls connected to a common pressure sensing point. These air compressors have been operating since the mid-1960s and are very difficult and expensive to maintain because parts are scarce and service companies with experience servicing this type of air compressor are difficult to find.

Pharmaceutical

This article is intended to show the relationships between risks and specifications, opportunities and responsibility in validation, and in particular, the use of modern and calibrated measurement technology in the sample chain.

Plastics

By making changes primarily focused on compressed air uses, Winpak, an international plastics products manufacturer based in Winnipeg, Manitoba, Canada, increased compressed air production capacity and reduced annual energy consumption by 33%. These benefits have been accomplished while the company was making the switch to lubricant-free compressed air to support product quality goals. This article discusses some of these changes and addresses measures that could be implemented in any compressed air system.

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

When the New York City Transit Authority (NYCT) set out to comply with local regulations calling for reductions in energy usage, it leveraged new air compressors for use in transit bus maintenance and repair – and took things to another level by recovering air compressor waste heat to provide hot potable water for the bus depot. The air compressor and heat recovery system, installed in spring 2017, is on its way to helping NYCT achieve the best energy savings possible.

Wastewater

The plant upgrades, in combination with a progressive management strategy, allows the plant to consume less energy and reduce its reliance on outside contractors for biosolids removal, resulting in total operational savings of approximately $60,000 per year.  The plant is also positioned to efficiently manage the area’s wastewater for decades to come.
As in most industrial categories, compressed air is critical to the operations of a plastics plant whether it is blow molding, injection molding, or other processes. The opportunities to improve supply side (compressor room) efficiency are similar to all industrial compressed air systems, but are even more prevalent in some plastics facilities, especially blow molding.
Most P.E.T. bottle-blowing machines require anywhere from 550 psig (38 barg) to 580 psig (40 barg) and an air flow of 247 cfm FAD (420 m3/hr) to 3700 cfm FAD (6290 m3/hr). The air compressor technology used most prevalently for this application is the double-acting, oil-free, water-cooled, reciprocating air compressor. With the higher pressures and air flows that are required, the P.E.T. bottle blowing market is a strong niche market for the double-acting oil-free reciprocating (piston) compressors.  
There are three main segments in Visteon's climate group are climate systems, powertrain cooling and engine induction. Climate systems include refrigeration compressors, fluid transport, heat exchangers, battery cooling modules, climate controls, auto defog/demist systems, and multi-zone HVAC systems. Powertrain cooling systems include heat exchangers (radiators, condensers, charge-air, exhaust-gas), airflow management, and diesel and hybrid thermal management. Engine induction includes air induction systems and intake manifolds.
Several days prior to our visit, during a cold winter evening, the lead air compressor in one mechanical room tripped off (apparently due to a fouled intake filter and low air flow through the machine). A crucial situation then developed: The "stand-by" unit did not start. Maintenance folks had to be called in to get a compressor running. That delay caused low plant air pressure, production curtailment and some defective product. They had yet to determine the conditions that caused the "no-start".
Compressed Air Best Practices interviewed Doug Barndt (Manager, Demand Side Energy-Sustainability), Joseph Gress (Principal Engineer, Demand Side Energy) from Ball Corporation and Chris Gordon (Compressed Air System Specialist) from Blackhawk Equipment.  
Encouraged by government regulators, the conversion to waterborne paints is now moving into the collision repair and refinishing industry. The conversion to waterborne paints is proving to have implications for the compressed air systems in the shops. This document provides a checklist of compressed air system topics to ensure a successful conversion to waterborne paints.
Nitrogen gas provides a number of diverse uses for a wide variety of manufacturers. As a sister function of compressed air, on-site nitrogen generation can provide additional opportunities for cost savings and other efficiencies for manufacturers who shift from delivered liquid nitrogen service.
This article describes a compressed air retrofit project implemented at Kellogg’s Eggo factory located in San Jose, California. Kellogg’s continues to realize both annual energy savings and quality improvements because of the upgrade. In addition, Kellogg’s received a substantial utility incentive from Pacific Gas and Electric Company, which was based on the achieved energy savings.
Power Smart® efficiency measures for compressed air systems at Tolko’s paper mill and sawmill at The Pas are saving the company more than $125,000 a year.  
Pneumatic air cylinders play a major role in allowing a modern sawmill to produce at the high-speed production rates required. Stable air pressure is critical to allow the air cylinders to respond in a timely manner and avoid any production delays.