System Assessments

Thought Leaders on System Optimization Past & Future

Edited by Troy Dreier, Senior Editor, Compressed Air Best Practices® Magazine

We asked a hand-selected list of original equipment manufacturers, independent compressed air system sales and service companies, manufacturing plants and independent system auditors to share their thoughts, highlighting the changes they’ve seen over the past 20 years, then predicting what the next 20 years will bring.

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Boost Performance with On-Site Oxygen and Nitrogen Generation

By Jatinder Tiwana, CEO, Specialty Gas Canada

The impact of compressed air on industries globally is undeniable, spanning from small tire shops to vast oil and gas sectors, as well as specialized domains like laboratories and pharmaceuticals. Amid this industrial transformation, many have taken control by employing in-house air compressors, air dryers, and related equipment to autonomously generate compressed air. In-house compressed air generation eliminates the need for relying on external sources, whether through cylinder bulk packs, Dewars, or tankers delivering compressed air.

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Advanced Vacuum Generation Reduces Maintenance

By Dr. Fabian Fahlbusch, Head of Content Marketing, Busch Vacuum Solutions

Industrial ceramics have been produced in Hermsdorf, near Jena, since 1890. In the past, high-voltage insulators; now, ceramic honeycomb bodies for heat exchangers, ventilation and emission control systems. They have always kept up with the times, developing innovative materials, products and state-of-the-art production processes to do so.

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In the Spirit of Improvement - Nation’s oldest distiller takes practical approach to compressed air system upgrade

By Brian Keelen, Vice President, Air & Gas Technologies and Brian Sorbello, Northeast Region Manager, Rogers Machinery

Laird & Company has been pioneering and perfecting Applejack brandy for 325 years. In 1698, William Laird immigrated from County Fyfe, Scotland to Monmouth County, New Jersey, bringing nothing but the distillation skills of his homeland with him. Keen to experiment with the ingredients of the New World, William began to dabble in the distillation of the most abundant crop in the area – apples.

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Translating Compressed Air System Data Into Meaningful Information

By Hank Van Ormer, Technical Director, APenergy

This article dealt with all the various conditions that can and do affect the performance capacity of various types of air compressors in actual flow capacity (SCFM at site conditions).

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Food Safety Design Tips for Pneumatic Systems

By Steve Bain, Industry Segment Manager Food & Beverage, Festo US

Current Good Manufacturing Practices (cGMPs) under FSMA CFR Title 21 117.40 is the cornerstone of this food safety effort. Title 21 details the cleanability and cross contamination standards that plants must meet so that food is deemed safe. The following are tips for updating existing pneumatic systems in food and packaging and what to look for when purchasing new systems.

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Facility Evaluates Air Compressors to Increase Nitrogen Purity with Nitrogen Generators

By Hank Van Ormer, Technical Director, APenergy

Over the last two decades, there has been a significant increase of manufacturing facilities deciding to produce their own nitrogen on-site, using compressed air systems and nitrogen generators. They are choosing on-site nitrogen generation, instead of purchasing and receiving deliveries of nitrogen by the cylinder or having a “Nitrogen Over the Fence” supplier.

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Vacuum Fundamentals: Process Applications & Oil-Free Technology

By Bryan A. Jensen, Engineered System Solutions Manager, Rogers Machinery Company

A ‘Process’ application, is one where it’s all about controlling the contents of a vessel, pipeline, or chamber. What is the gas makeup inside the vessel? How much of it is in there? All means to control a chemical and/or thermodynamic reaction so that we add value to some base ingredients to convert them into a marketable product.

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Compressed Air Audit Details Two Energy Saving Projects for Maintenance Teams

By Don Van Ormer, Senior Auditor, APenergy

In this article, we will provide detail on the characteristics of the baseline system and then share the energy-saving work identified in two projects. These two projects represent work which can be performed by the maintenance teams in every plant. These are also project opportunities we find in almost every plant we visit. The two projects are to (1) repair/replace condensate drains wasting compressed air and (2) to perform a compressed air leak survey.

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Growing Dairy Product Processor Improves Uptime with Compressed Air Audit

By Don Van Ormer, Senior Auditor, APenergy

There were two situations brought to our attention. The first was that production at times was having to slow down, or even stop, due to compressed air system pressure falling below the required levels. The second reason was due to reports, from plant personnel, of compressed air moisture problems negatively affecting the bag life of the dryer baghouses.

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Compressed Air System Optimized at Cheese Packaging Plant

By Hank Van Ormer, Technical Director, APenergy

This assessment identifies a path to reduce the energy consumption from \$85,000 to \$51,000 per year. This can be done with little capital by fixing poppet-valve control problems on the air compressors and reducing flow and pressure requirements. Due to article space limitations, this article does not provide detail on the flow reduction projects. It focuses only on the impact these projects have on the air compressors and provides readers with a template on the information they should have on their units, by shift.

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