A focus on sustainable products and packaging, in combination with a passion for quality, has resulted in considerable growth for the firm. Plans to add production lines at facility #1, in turn, drove the need to address the plant’s faltering compressed air system.
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.
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.
The initial cost of a nitrogen generation system may be greater than high-pressure cylinders and liquid nitrogen containers, but most companies will reach a return on investment within 12-18 months with proper sizing of the system based on process demands. Breweries typically experience savings associated with gases of 50-75% by switching to on-premises nitrogen generation. If a regular maintenance schedule is followed, PSA nitrogen generation systems can have a life expectancy of 15-20 years.
The dust is collected on the bag or fingers, and when the cake of dust is of appropriate thickness and structure, a pulse or pulses of compressed air hits or shocks the bag and knocks the cake off. This pulse may sometimes be accompanied by physical shaking and even reverse air flows, depending on design.
A premium whiskey distillery was seeking to renew their compressed air system and meet their corporate mandate in making their production facility more efficient. The first step on the road to improvement was having their compressed air system assessed. This article discusses some of the findings of the system study, which saved significant energy, improved system reliability, and captured a significant utility incentive to help with the study costs and the cost of a new compressor.
The current cost to operate the compressed air system is \$139,100 annually, and the proposed measures will reduce it by \$50,700 annually. The proposed cost to complete the measures is $47,600 providing a simple payback of 11 months. The cost included in the Action Plan includes engineering, project assistance, services to maintain the gains, and a 10% contingency.
Sustainability is a high priority for today’s consumer packaged goods (CPG) companies. Driven by environmental responsibility, government regulations and customer preferences, CPGs are actively seeking ways to decarbonize their packaging lines and use eco-friendly packaging materials. Many have started monitoring the energy consumption of their equipment in real time and upgraded critical areas of their packaging processes using two key technologies: pneumatics and ultrasonic welding.
The 2022 International Production & Processing Expo (IPPE), was held January 25-27, 2022 in Atlanta with more than 500,000 square feet of exhibit space and 1,140-plus exhibitors. Attendee numbers had not been released when this was written. Sponsored by the U.S. Poultry & Egg Association, American Feed Industry Association and the North American Meat Institute, IPPE is the world's largest annual poultry, meat and animal food industry event of its kind.
Growing awareness of the importance of food grade lubricants for consumer safety and Hazard Analysis and Critical Control Point (HACCP) regulations, as well as increasing consciousness about Kosher and Halal registrations triggered an increasing demand for high performance food grade lubricants.
“Our view is always from the perspective of the value chain from the raw materials to the end product,” Wellendorph said. “How do we work with our suppliers who supply us? How do we look at our own manufacturing to avoid waste? Then, how can our equipment minimize the amount of energy or water it uses when processing and packaging customers products? It’s more than just focusing on ourselves.”