Industrial Utility Efficiency    

Industries

Outsourcing maintenance agreements for compressed air systems is commonplace in the food and beverage industry. The maintenance programs are often performed by air compressor distributors, who are experts in the specifics of the air compressors and compressed air systems they sell and service.

Auto

The Ford Motor Company Kentucky Truck Plant (KTP) not only manufactures upscale SUVs and pickup trucks painted in wide variety of stellar, high-quality colors and finishes –  it does so cost-effectively by conserving annual compressed air energy of approximately 9.2 GWh thanks to a major overhaul of the plant’s compressed air system.

Bulk

Reverse pulse type dust collectors often represent a challenge to compressed air energy efficiency, and sometimes throw a wrench into the works by causing huge air pressure fluctuations, high transient flows and just plain large leaks. This article discusses this type of dust collector, often installed in food processing plants, and gives some real-life examples of problematic installations. Some suggested measures are mentioned to ensure your dust collectors keep running in a trouble-free manner.

Food

Electricity and compressed air play an important role in the thermal and kinetic processes for everything from mixing and extruding the ingredients, deep-freezing to -13°F (-25°C), dipping into various chocolate coatings through to final packaging. Energy efficiency is therefore right at the top of Unilever’s list of priorities. As part of the Unilever Sustainable Living Plan, this global corporation has succeeded in saving more than $186 million in energy costs from efficiency improvements in production alone since 2008.

Medical

The air is delivered through a distribution piping system that ends with a medical air outlet within the room. Outlet requirements per room are governed by American Institute of America (AIA) Guidelines for Design and Construction of Hospitals and Healthcare Facilities. Equipment is plugged into the medical air outlet to treat the patient. Many studies have been done determining the load required for medical air compressors. The sizing can be calculated using several methods. 

Metals

One topic up for discussion in the metal fabrication industry is the assist gas used for laser cutting. The assist gas is fed into the laser head, and surrounds the laser as it cuts the work piece. The assist gas is intended to facilitate a smoother cut, increase cutting speeds and productivity, and to prevent discoloration, oxidation, scale, burred edges and other defects that can arise from the hot cutting temperatures. Since Nitrogen is an inert gas, it is used as an assist gas on many laser cutting systems to prevent oxygen from coming into contact with the metal while it’s being cut. Nitrogen is supplied to users in traditional cylinders, and with on-site nitrogen generation.

Paper

The facility has a compressed air system consisting of four, 200-horsepower (hp) two-stage water-cooled lubricant-free reciprocating air compressors. The air compressors are controlled individually with local pressure switch controls connected to a common pressure sensing point. These air compressors have been operating since the mid-1960s and are very difficult and expensive to maintain because parts are scarce and service companies with experience servicing this type of air compressor are difficult to find.

Pharmaceutical

This article is intended to show the relationships between risks and specifications, opportunities and responsibility in validation, and in particular, the use of modern and calibrated measurement technology in the sample chain.

Plastics

By making changes primarily focused on compressed air uses, Winpak, an international plastics products manufacturer based in Winnipeg, Manitoba, Canada, increased compressed air production capacity and reduced annual energy consumption by 33%. These benefits have been accomplished while the company was making the switch to lubricant-free compressed air to support product quality goals. This article discusses some of these changes and addresses measures that could be implemented in any compressed air system.

Power

A newly constructed ethanol plant experienced control gap issues shortly after comissioning.  This article discusses the cause of the issue and how the problem was solved.

Printing

The Trinity Mirror Group print works on Oldham is one of the UK’s largest newspaper printers. The nine presses in the facility produce around 1million papers every day, including the Independent, the Daily Mirror and a range of local, regional and sports titles. Printing on this scale does not come cheap in energy terms, however. The plant’s annual electricity bill is in the order of £1.5millon. With energy prices on the rise, and a strong desire to improve environmental performance and reduce its carbon footprint, the plant’s management has recently embarked on a project to cut energy use substantially.

Transit

When the New York City Transit Authority (NYCT) set out to comply with local regulations calling for reductions in energy usage, it leveraged new air compressors for use in transit bus maintenance and repair – and took things to another level by recovering air compressor waste heat to provide hot potable water for the bus depot. The air compressor and heat recovery system, installed in spring 2017, is on its way to helping NYCT achieve the best energy savings possible.

Wastewater

The plant upgrades, in combination with a progressive management strategy, allows the plant to consume less energy and reduce its reliance on outside contractors for biosolids removal, resulting in total operational savings of approximately $60,000 per year.  The plant is also positioned to efficiently manage the area’s wastewater for decades to come.
Brewing is normally broken down into four stages-malting, mashing, boiling and fermenting. The complex chemical processes begin with a few simple ingredients - hops, grain, yeast and water. Recently there have been technological advancements to safeguard that these steps are attained accurately, efficiently and with cost-savings. One particular improvement is the use of nitrogen during the brewing process. The addition of an onsite nitrogen generator allows brewers to reduce their nitrogen costs, eliminate downtime, and reduce safety risks related to bulk gas cylinder delivery and changeouts.
Compressed air is a critical aspect of brewing craft beer and no one understands that better than Five Churches Brewing, which recently looked to MidState Air Compressor, Inc. to recommend and install an appropriate compressed air system for virtually every aspect of beer production including brewing, canning and keg washing.  
By addressing inappropriate uses of compressed air and making changes to the compressed air production side of their compressed air system, a distiller of fine alcohol products reduced its energy consumption by 30%, saving $16,600 per year in energy costs - with more potential savings possible.
For more than 20 years, Hungarian-based Doroti Pack Ltd. has specialized in the production and servicing of state-of-the-art packaging machines. Their focus is on developing, manufacturing, producing and selling premium-quality packaging equipment, including their line of DorPack thermoforming machines which are often used for food products such as fresh meat, fish, dairy products, bakery ware, confectionery and ready-cooked foods. Dorati Pack chose to incorporate Aventics pneumatic components in latest thermoforming machine for optimal productivity and machine longevity.
Experienced auditors become wary when they see desiccant dryers installed in customers’ plants. These dryers are required when a plant needs instrument-quality compressed air, or when compressed air piping is exposed to freezing temperatures. However, while desiccant dryers can gain this level of quality, the energy cost of stepping up from a dewpoint of 35 oF to a level of -40 oF increases quite considerably. To attempt to reduce the energy costs of drying to these low levels, heated blower desiccant styles may be used. This article describes three common desiccant dryer types, as well as some experiences, good and bad, with heated blower types.
This major food manufacturing plant in the Midwest uses compressed air and onsite nitrogen generation to operate multiple snack production and packaging lines. The plant spends an estimated $430,344 annually on energy to operate its compressed air system based on an average rate of 4.5 cents per kWh.
On a recent project, at a polyethylene terephthalate (PET) blow-mold and filling operation, a very effective measurement plan resulted in a full synchronization of the supply side air to blow molds with significant reduction in total air use and increases in productivity and quality.  
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.
Many food processing plants are already using oil-free compressed air at a low-pressure dewpoint. This has required the use of two-stage oil-free screw air compressors, centrifugal air compressors and other technologies, as well as regenerative dryers of one type or another. The most common oil-free air compressor in industry is the two-stage “dry screw” machine and the most common regenerative dryer type is the heatless type. These are combined in many food processing, pharmaceutical, and high-tech plants.    
Machines for filling milk or juice must often work around the clock. Given the critical importance of uptime, Elopak opted for Aventics food-compliant pneumatics when developing its E-PS120A - the first fully aseptic filling machine for gable top packaging. With an output of up to 12,000 cartons per hour, disruptions and downtime are not welcome with the aseptic filling machine.