Technology

Production processes get their energy from the air stored at higher pressure in the piping distribution system. The air compressors simply replenish the air that is consumed. It is an important distinction to make. The energy input in compressing the air is supplied to the connecting pipes for delivery to the various demands throughout the facility.

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.

“First there are the old conventions. The majority of compressor houses still employ fixed speed compressors and a cascaded pressure switch control system. This arrangement will be familiar to many, but it is outdated and inefficient, and needs to be changed. There is a comfort factor with familiar technology, which is exacerbated by constant time pressure due to other day-today responsibilities and a lack of information and good advice on what can be achieved.”

“Compressed air systems with multiple compressors operating to supply demand requirements present unique challenges in compressed air system control schemes.”

A Tier 1 automotive plant was spending \$364,259 annually on electricity to operate their compressed air system. This figure was expected to increase as electric rates were forecasted to rise from their current average of 7.16 cents per kWh. Our firm, Air Power USA, conducted a full supply and demand-side compressed air system assessment. The set of projects recommended by the assessment, would reduce these energy costs by \$218,670 or 60%.

Kneeling modules are quickly becoming the centerpiece of accessible vehicle equipment. This trend began with passage of the Americans with Disabilities Act (ADA) in 1991. Prior to the ADA, about 40% of all transportation vehicles were accessible to persons with disabilities.

Much attention and expense is often directed towards optimizing compressor control, clean-up equipment, system pressure / flow control and main system piping in an attempt to maintain adequate and stable pressure at the end use. Often forgotten are the components of the distribution system between the main system header and the end use.

In the realm of pharmaceutical production and packaging, the two most important factors with compressed air are reliability and quality. In pharmaceutical plants, our customers have emphasized this reoccurring theme over and over to paint the clear picture that reliable and high-quality air are king.

This West Coast pharmaceutical facility has a very clean and organized compressed air system. All equipments is in good working order in the compressor room. The compressor room itself is very clean and well ventilated. The management requested a compressed air system audit for two reasons:

Dewpoint is defined as the temperature to which a gas (e.g. air) must be cooled, at constant pressure, for water vapor to begin to condense to liquid water. In other words, when the dewpoint temperature has been reached, the gas is fully saturated with water vapor.