Industrial Utility Efficiency

Metals

IPS Advises Midwest Industry on Compressed Air Efficiency

By Troy Dreier, Senior Editor, Compressed Air Best Practices® Magazine

IPS supplies compressed air to a lot of machinery running outdoors, such as dust collectors and feed mills on grain elevators, as well as to other equipment in environments lower than 32°F (0°C). Temperatures that low require desiccant dryers. Hoffman helps his customers sort out their options and determine which type of desiccant dryer – heatless, heated purge, heated blower purge – is ideal for their needs.

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20 Years of Case Studies: Plants Sharing Best Practices

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

For 20 years, Compressed Air Best Practices® Magazine has published articles focused on helping manufacturers reduce power demand, lower water consumption, and improve the performance of compressed air, cooling, blower and industrial vacuum systems. In this article, we highlight a sampling of those stories across the following industries: Plastics and Packaging Food and Beverage Automotive and Transportation Cement, Building Materials, and Mining Metals, Pulp, and Paper Pharmaceuticals, Healthcare, and Research Wastewater Treatment 
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Advanced Compressor Technologies Solves Oversupply Problem

By Troy Dreier, Senior Editor, Compressed Air Best Practices® Magazine 

A Southern Indiana office furniture plant was wasting hundreds of dollars per day because its oversized VSD air compressor could not turn down low enough to match reduced demand after a shift to metal fabrication. To avoid drive faults, the plant vented compressed air to create false load. The audit revealed 300 cfm of wasted air—about $400 per day—and led to a redesigned system using a fixed-speed compressor for base load and a VSD unit for trim. The new configuration eliminated artificial demand and cut compressed air energy use in half, setting the stage for further savings through advanced sequencing, storage, and demand control.
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Kirsh Foundry Drives Energy Efficiency with Compressed Air Optimization

By Juan Espindola, CEM, Facilities Optimization Leader, The Wasmer Company

The energy savings amounted to 550,873.5 kWh per year, resulting in a reduction of \$49,579 in energy costs annually. Additionally, nitrogen savings were significant, with annual expenses dropping by \$8,602 due to the installation of the on-site nitrogen generator. Overall, the project achieved total annual savings of \$58,181, with implementation costs of \$74,676 and an impressive payback period of just 1.28 years.
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Compressed Air, Nitrogen Generation and Chiller Systems at Fabtech 2023

By Roderick M. Smith, Editor, Compressed Air Best Practices® Magazine

FABTECH 2023, a leading event for metal forming, fabricating, welding, and finishing, successfully wrapped up its four-day run at Chicago's McCormick Place, achieving significant milestones for attendance, exhibitors, and show floor size. The 2023 show floor, spanning an impressive 825,325 square feet across three exhibit halls, featured an extensive showcase of over 1,500 world-class suppliers. 
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Air Compressor Control Lessons Learned at Metal Products Company

By Ron Marshall, Marshall Compressed Air Consulting

Their system was designed and built to achieve premium performance, yet in a recent compressed air assessment the numbers showed their system had surprisingly poor performance, and worse, their staff was unaware of the problems. This article discusses some of the challenges faced and some future solutions that could get their system back to higher performance levels.
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Small Piston Air Motors Save Big Energy While Ensuring Safety

By Jerry Zolkowski, Industrial Energy Management Principal Engineer, Consumers Energy Business Energy Efficiency Programs

Vane motors can run at much higher speeds (2000 rpm and up), but piston motors tend to turn much slower – less than 1000 rpm. For slower speed applications, vane motors are mated with a gear reducer and called a gearmotor. The gearmotor can produce the higher torque and slower speed needed for some applications, but the gear reducer can add some drivetrain loss. While a piston air motor may not be able to replace a vane motor where high speed is needed, it can be a good choice for high torque/low speed applications.  
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DOE Better Plants Partners Get Serious About Compressed Air Systems

By Robert Lung, BGS, with contributions from: Ed Willhite, Schneider Electric; Stephen Tankersley, Ring Containers; Marco Gonzalez, Waupaca Foundry; and Darwin Jaeger, Plastics Engineering Company.

Compressed air is used in all the company’s plants and is often the single largest energy end use within them. As a result, compressed air energy-saving measures are often replicable across the company and offer significant positive impacts. One area of focus is with compressed air leaks since they are “the best low hanging fruit to focus on and they always keep popping up and waste energy”.
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Metal Fabricator Measures Nitrogen Use, Receives a Surprise

By Ron Marshall, Marshall Compressed Air Consulting

Nitrogen is used in many facilities for a variety of purposes. The most common source of N2 is through the use of bulk liquid storage. A plant owner was recently surprised to learn that a large portion of his N2 was disappearing, without ever being used by his production process. This article discusses where it went and what we could do about it.
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Compressed Air Supports Growth at Roush Yates Manufacturing Solutions

By Mike Grennier, Compressed Air Best Practices® Magazine

“I’ll say this politely. At the end of the day, we shouldn’t have to worry about compressed air, right? We’ve got more important things to worry about,” English said, adding how a recent partnership with Atlas Copco Compressors and other decisions associated with compressed air have hit the mark. “Without clean, compressed air we wouldn’t be able to complete our day-to-day activities. We’re relieved it’s something we don’t need to worry about.”
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Re-engineered Compressed Air System Scores Perfect “10” at PC Forge

By Mike Grennier, Compressed Air Best Practices® Magazine

Since completion of the system upgrade in the fall of 2020, PC Forge is on track to save an average of 1.9 million kWh and $266,000.00 per year in energy costs – and increase the production capability of its forging operation by 40%. The project also achieved a one-year payback with a \$245,000 incentive from Government of Ontario’s utility Independent Electricity System Operator (IESO).
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