Industrial Utility Efficiency    

Technology

In the food and beverage industry, the moment a product leaves the production line, the clock starts ticking down to when that product will no longer be viable for sale or consumption. To combat the clock, modified atmospheric packaging (MAP) techniques are used to help maintain product freshness and increase shelf life. Nitrogen is the most cost effective, efficient and widely used industry solution for a company’s packaging needs—whether it is for manufacturing cheese, coffee, dried snack foods, or fresh and ready-to-eat (RTE) foods. MAP also helps to decrease chances of contamination or spoiling, keeping products on the market for longer and ultimately increasing the reach of distribution.

Air Compressors

As an industrial distributor for 65 years, C.H. Reed, Inc. has been providing ideas, concepts and sustainable solutions to help manage issues associated with three key areas of industrial plants: compressed air systems and equipment; assembly tools and ergonomic material handling; paint finishing and fluid handling equipment. Compressed air has always been a strong focus for C.H. Reed, and it’s a common thread running through all of its product families.

Air Treatment

Plastic injection molding is a common process in manufacturing, and it can be used to produce just about anything. To create a part, molten plastic is injected into a hollow mold, where it is formed and cooled before being ejected from the cavity. Plastic injection molders make a seemingly limitless range of products, from fishing tackle boxes and kayak paddles to tooth brushes and miniscule medical devices.

Blowers

High speed bearing technology is applicable for aeration blowers operating at much higher speeds than the typical 60Hz, 3600RPM for cast multistage units. High Speed Turbo (HST) units are usually single stage (though some utilize multiple cores) and rotate from 15,000 to 50,000RPM. At such high speeds, standard roller bearings cannot offer the industry standard L10 bearing life. Two types of bearing technologies have come to dominate the wastewater treatment market for these types of machines: airfoil and magnetically levitated. Often the two technologies are compared as equals, however, in many significant ways they are not.

Compressor Controls

In this article, Chad Larrabee from Ingersoll Rand writes about today’s status quo in most air compressor rooms – a group of air compressors all running off their individual controllers with different control schemes attempting to coordinate them. Larrabee then describes the advantages of a smart system controller, which can direct " compressors to respond to one common signal … dynamically matching compressed air supply with demand.” He concludes by outlining the benefits of remote connectivity and automated alerts for maintenance staff.

Instrumentation

A modern dairy without compressed air is nowadays no longer imaginable, and it is used primarily for driving control units and machinery. Approximately 60 percent of the compressed air generated is used for packaging lines. However, compressed air is one of the most expensive energy sources in dairies. Even in carefully maintained compressed air systems, about 20 percent of the generated energy is lost through leaks. In particular, vacuum leakages in separators result in high energy losses. A small leak can cost up to several thousands of Euros a year.

Pneumatics

The design of wastewater treatment plants is changing, and it has something to do with LEGO® bricks. More specifically, it has to do with how large and complex LEGO structures are built. If you follow the instructions carefully, you build module after module, eventually piecing them together to create a fully functional and cohesive unit.

Vacuum

It’s one thing to move materials during the production process, but when it’s a finished product on the packaging line, choosing the right material handling system is essential. Getting it wrong results in squandered production time when product loss occurs, and wasted raw materials.

Cooling Systems

There are six basic types of cooling systems that you can choose from to meet the cooling needs of your load. Each one has its strengths and weaknesses. This article was written to identify the different types of cooling systems and identify their strengths and weaknesses so that you can make an informed choice based on your needs.
Sometime in mid-2015, I received a call from a project engineer at a major plastics firm. He had a troubling issue with one of his PET bottle plants. The bottom line was this: They could not run all five high production blow-molding machines at one time—even though they were able to do so 18 months previously.
Any modern food manufacturing facility employs compressed air extensively in the plant. As common as it is, the potential hazards associated with this powerful utility are not obvious and apparent. Food hygiene legislation to protect the consumer places the duty of care on the food manufacturer. For this reason, many companies often devise their own internal air quality standards based upon what they think or have been told are “best practices.” This is no wonder, as the published collections of Good Manufacturing Practices (GMPs) that relate to compressed air are nebulous and difficult to wade through.
Compressed Air Best Practices® Magazine and the Compressed Air and Gas Institute have been cooperating on educating readers on the design, features, and benefits of centrifugal compressor systems. As part of this series, Compressed Air Best Practices® (CABP) Magazine recently caught up with Rick Stasyshan, Compressed Air and Gas Institute’s (CAGI) Technical Consultant, and Ian MacLeod of CAGI member company, Ingersoll Rand. During our discussion, we reviewed some of the things readers should consider when installing a centrifugal compressor system.
Air-operated double diaphragm (AODD) pumps are common to many manufacturing facilities. As estimated by veteran compressed air auditor Hank van Ormer of Air Power USA, approximately 85 to 90 percent of plants in the United States have AODD pumps. They are used for all kinds of liquid transfer applications, like those found in chemical manufacturing, wastewater removal, and pumping viscous food products.
There is always something new to learn about compressed air systems – particularly in regards to compressed air dryer installations. As I discussed in Part 1 of this series, you can make compressed air dryer installations more reliable by understanding the consequences of any modifications you make to the system.  As a continuation of those ideas, Part II explores more ways to make a dryer installation more reliable. Discussions include: the difference between operating a desiccant dryer in a fixed cycle opposed to demand mode, what happens when you operate a heated desiccant dryer with the cooling air turned off, and how to deal with the unintended consequences of dedicating a desiccant dryer to a compressor. 
One of the statements made in the Compressed Air Challenge’s Fundamentals of Compressed Air Systems seminar is that improvements can always be made to every compressed air system, including new ones. The statement definitely applies to a Canadian pork processing facility built a few years ago. This article is based on a compressed air audit performed two years into the life of a brand new plant. The audit found numerous problems and made recommendations that helped reduce plant compressed air operating costs by 60 percent. 
Critical applications — such as semiconductor manufacturing, food processing and automobile spray finishing — require high quality, clean compressed air. Otherwise, those manufacturing facilities are doomed to costly rework, product recalls and a tarnished reputation. “In semiconductor manufacturing, a small particle can ruin one of the die on a multi-die semiconductor wafer,” explained Dan Ryan, Engineering Manager, Parker Hannifin Corporation – Gas Separation and Filtration Division. “Even when it comes to things like painting automobiles, a few small, invisible particulates, depending on the makeup of them, can actually cause a visible flaw in the paint job.”
The speaker line-up is vendor-neutral and structured to help air compressor sales and service companies improve their businesses. Presentations included an economist updating members on the state of the economy, a utility incentive program update from Clear Result, and a Q&A Session featuring Ron Nordby and Bill Scales.
The World Energy Engineering Conference provides many educational tracks for energy managers to attend, including several hosted by the Environmental Protection Agency’s ENERGY STAR® program and the Department of Energy’s Better Buildings, Better Plants Program. I was fortunate to sit in on several of the Industrial Energy Management tracks, in which energy mangers from companies like Raytheon, Nissan North America, and General Mills shared success stories and strategies for running energy management programs.
Proper air preparation significantly increases the process and production reliability of machines. Particles, water and oils in compressed air reduce the service life and functionality of components and systems. They also impair productivity and energy efficiency. In this article, a variety of air filtration and air treatment products are outlined and discussed, along with ancillary equipment like drains. Additionally, the article provides an overview of the compressed air purity classes defined by ISO 8573-1:2010.