Industrial Utility Efficiency

Compressor Controls

As part of its ongoing corporate initiative to find ways to reduce its energy bills, and the costly impact on the bottom line, a cleaning products plant, located southwest of Chicago, recently focused on improving their compressed air system operation. This company is a global leader in water, hygiene and infection prevention solutions and services. This article discussed their efforts to improve the operation of their compressed air system by implementing an innovative compressed air monitoring and control system.

Remote Monitoring Takes Off for Aerospace Manufacturer

In the absence of the control system, the air compressors were loading and unloading according to pre-set pressure bands, which forced the system to operate at higher pressures and run inefficient combinations of compressors in order to effectively match air demand. When switched on, irrespective of air demand, the control system was able to control all compressors on a single, tight pressure band and efficiently match output with demand.

AZEK Compressed Air Project Enhances Reliability While Saving Energy

The AZEK Company is a producer of durable and low maintenance building materials, and like many manufacturers, it found its compressed air system to be time consuming and expensive to keep maintained. But that changed after the company replaced its outdated and faulty compressed air system with a new design that includes technically advanced air compressors, dryers, receiver tanks – as well as controls to provide better control of the entire system and achieve optimal performance.

Networked Air Compressors Operate in Harmony at Automotive Manufacturer

When an automotive company added a new 200-horsepower (hp) rotary screw air compressor and accompanying dryer to a satellite building at its Chicago-area assembly plant, it needed a cost-effective way to integrate the equipment into its existing compressed air network. Doing so would allow plant personnel to easily monitor the air compressor’s performance and ensure it operates in harmony with the plant’s centrifugal air compressors. Importantly, it would contribute to efficient and reliable air compressor operation at all times.

How to Manage Compressed Air Systems During High-Demand Events

One of the challenges with compressed air system design is dealing with periodic large flow demands. Food and beverage manufacturers are among those process industries that often face these events. Adding in the compressed air demands of onsite packaging further adds to the task.

Dutch Glass Container Plant Compressed Air System Makeover Increases Uptime and Energy Savings

To improve the delivery of compressed air at the plant, which is supplied by low-pressure and high-pressure compressed air systems, the manufacturer took an important first step by using airflow meters to monitor and measure the performance of both systems. Subsequent planning based on actionable data led to a unique compressed air system upgrade that increases the plant’s ability to maintain peak production of high quality glass bottles and containers at all times – while saving \$150,000 per year in energy costs. The project also delivered a payback of less than two years.  

Is Your Controller a Blast From the Past?

Advances in phone technology dramatically improve their function and our experience. More storage, faster speeds, enhanced communication options, bigger and brighter display….and so on. As a result, today’s phones are significantly more powerful – improving our productivity and changing our lives. As for the technology laggards, obsolescence eventually prompts change. Repairing or replacing parts and accessories on the old phones is an increasing challenge. Eventually they have to succumb to technology.

Compressed Air Guidelines for Varying Production Levels

Companies will experience periods of increased production, as well as periods of slower or stopped production. It’s the nature of being in business. Understanding the implications of these business shifts for compressed-air installations (the powerhouse behind a facility’s production) is key for ensuring that air compressors remain functional and efficient. Here are guidelines to ensure your facility’s compressed-air system operates at top performance, no matter the speed of production.

Tier 1 Automotive Supplier Saves Energy Upgrading Centrifugal Air Compressor Controls

A Tier 1 automotive supplier was concerned its compressed air system was not operating as efficiently as it could be. The situation called for a site visit and metering and evaluation of the company’s air compressors to generate a representative data sample that accurately captured the compressed air needs during typical production and non-production periods.