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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.
A flour based frozen foods manufacturer orders a compressed air efficiency audit. The audit establishes the cost of compressed air at $0.27/1000 cubic feet. The study finds the 116 pulse jet dust collectors represent the greatest opportunity for compressed air demand reduction and energy cost savings. A dust collector optimization study/service is suggested and the customer agrees to proceed. In this facility, pulse jet dust collectors are used to filter dust from raw materials entering the plant, for conveying and mixing of ingredients, and for the final packaged finished products leaving the plant.  
This article will focus on ISO8573-7 normative test methods and analysis for viable microbiological contaminants and how it can be fundamentally utilized in compressed air microbial monitoring plans. The quality of the compressed air must be monitored periodically to fulfill national and international standards. ISO 8573 is an available standard addressing compressed air quality. It consists of nine parts that address purity classes, specifications, and procedures. ISO 8573-7:2003, can be utilized across all industries’ compressed air microbial monitoring plans. It contains both informative and normative procedures but lacks any tested compressed air microbial specifications regarding colony enumeration limits for microbial plate counts.
A pharmaceutical plant, has had a compressed air assessment performed on two plant systems.  The studies uncovered poor compressed air production efficiency, high air dryer loss, and problems with high flow compressed air uses negatively affecting plant pressure. The plant implemented energy efficiency measures, on the two compressed air systems, saving 46 and 64 percent in energy costs respectively.
One of the most common problems in plants is low air pressure. One of the most common solutions is to purchase new air compressors. Often this advice leads to a poor return on investment with the company’s hard-earned money. Often the issues are related to demand, distribution, or both. Solving the wrong problem can be expensive from a capital and operating cost perspective. Determining root cause analysis may cost more up front, but will save tens if not hundreds of thousands of dollars long term.
The plant produces both molded and blow molded plastic parts on a 5 day per week, three shift schedule. Production and maintenance sometimes occurs on weekends, occasionally requiring the air compressors to run on a 24 x 7 basis so the practice was to leave the compressed air system always pressurized. The system consisted of three modulating lubricated screw compressors one sized at 150 hp and the others 125 hp (3 units), each controlled with their local compressor controllers.
The Pepsi bottling plant in Winnipeg, Manitoba has upgraded both their main 100 psi compressed air system and their 600 psi PET bottling system in two separate projects. The system improvements have saved the company both maintenance and electrical operating costs, and even reduced some winter heating demand.
Since 2002, Energy Trust of Oregon has saved and generated 728 average megawatts of electricity and 52 million annual therms of natural gas. This is enough energy to power Multnomah and Washington counties while heating Deschutes County homes. ETO has saved enough energy equal to the output of a power plant and reduced reliance on fossil fuels. In total, they have invested $1.5 billion to save customers more than $6.9 billion on their energy bills over time. They have also added $5.7 billion to the local economy, including $1.7 billion in wages, $312 million in small business income and employment equal to 4,700 full-time jobs lasting a decade.
This “nation’s largest regional show” has a 200,000 square foot exhibit floor and also has an interesting educational conference track. The show floor brings together the premier vendors of packaging and machinery with key decision makers in the Northwest’s food and beverage industry.
The International Production & Processing Expo (IPPE) is a collaboration of three shows - International Feed Expo, International Meat Expo and the International Poultry Expo - representing the entire chain of protein production and processing. The tradeshow focuses on bringing together leaders in the poultry, meat and feed industry from all over the world. IPPE’s global reach attracts more than 8,000 international visitors from 129 countries.
Their job is to brake the cars by gripping the wheels. They are operated either pneumatically or hydraulically, with Alton & Southern Railway’s system using the former. Considering much of Alton & Southern Railway’s compressed air piping system dated back to its 1960’s installation date, there were leaks. As of 2012, it was determined one and a half compressors were running at 100% capacity just to maintain leaks. This equated to about 1,500 cfm at a cost of roughly $180,000 in electricity annually.