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The System Assessment
Food
Many food processing plants are already using oil-free compressed air at a low-pressure dewpoint.
Plastics
The Pepsi bottling plant in Winnipeg, Manitoba has upgraded both their main 100 psi compressed air
Paper
Rockline Industries is one of the largest global producers of consumer products, specializing in
Printing
Several days prior to our visit, during a cold winter evening, the lead air compressor in one
Pharmaceutical
A pharmaceutical plant, has had a compressed air assessment performed on two plant systems.
Auto
Compressed air optimization measures adopted by PTMSB have reduced the consumption of compressed
Bulk
One of the most common problems in plants is low air pressure. One of the most common solutions is
Transit
When the New York City Transit Authority (NYCT) set out to comply with local regulations calling
Metals
Chicago Heights Steel, Chicago Heights, Ill., leveraged an advanced data monitoring system and
Medical
Helium is a precious noble gas that has become invaluable for leak detection, as well as cooling
Power
Nuclear power plants produce electricity for people, business and industry. Electricity is
Oil & Gas
Petro Chemical Energy, Inc. (PCE) specializes in energy loss surveys for the refining and chemical
Wastewater
Wastewater treatment processes have come a long way in the past century, but demand continues to
After getting its start manufacturing cost-effective products to the healthcare industry, 40 years later, 1888 Mills has become the fourth largest towel manufacturer in the world, and the largest towel manufacturer in the U.S. With facilities in the United States, Pakistan and Bangladesh, 1888 Mills’ towels are used in almost every corner of the world. 1888 Mills is recognized as a leader in innovation in the textile industry and produces 176,000 pounds of towels per week.
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To address a mandate for cutting operations energy usage at facilities by 25 percent without major capital expenditures, a major manufacturing company set its sites on better control of its compressed air systems. The project, implemented at 10 manufacturing plants over the course of three years, saves the company $977,093 annually in energy costs – and was completed with zero out-of-pocket costs.
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By finding a better way to control and manage its compressed air system, North American Lighting, Paris, Ill., has reduced its total compressed air energy use by 27 percent – and in the process – saves over 1,100,000 kWh/year for a total annual savings of $91,000. The project also achieved a payback of less than one year.
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A food processor in Western Canada hired an auditor to assess the energy efficiency of its compressed air system. The results revealed surprises about the operation of some important elements of the system, and detected that the air compressors were having control gap problems. Additionally, the audit led to initial energy savings of $20,000 – and identified the potential to achieve overall operational savings of 45%. The following details some of the audit findings and results.
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