Industrial Utility Efficiency


Electronics applications typically run their tooling requiring Process Vacuum based on differential pressure from barometric; that is, they control their PVAC pumps to “Inches of Mercury Vacuum”. This is because the parts and pieces being manipulated by vacuum are of certain sizes, shapes, and weights. If the differential pressure across the part is not great enough, then the tooling will fail and result in a loss of product, adverse impact to quality, and production downtime. 

A Kroger Company Bakery Saves Energy

Recently, The Kroger Company’s Indianapolis bakery identified the use of compressed air in a blow-off and conveyor gap transfer as a major source of energy loss and cost waste. According to the U.S. Department of Energy, “inappropriate use” of compressed air like blow-off produces high pressure atmosphere bleed leading to significant energy loss and unnecessary operational costs. Carrying a 10-15% efficiency return (according to the Department of Energy), compressed air applications can often be achieved more effectively, efficiently and less expensively with alternative solutions using a high flow rate and moderate pressure.

Protection Against Water Hammer Damage

One major problem that causes severe damage or system failure for any water treatment station is water hammer shock waves. “Water Hammer” or “Hydraulic Shock” is a pressure surge or shockwave resulting when a fluid (usually a liquid but sometimes also a gas) in motion is forced to stop or change direction suddenly (momentum change). The reversed momentum then continues to multiply the further it travels before being stopped.

Blower Advancements for the Wastewater Industry

"The Numbers Don’t Lie". It’s a popular saying everyone has heard before, applied to a variety of situations – political statistics, figures backing up an athlete’s performance and budget data.

Thirty percent is a big number. Applied to the above scenarios, it could entail a landslide victory or a hitter gaining entry into the Baseball Hall of Fame. But just imagine, if the manager of a wastewater treatment facility were to trim 30 percent from their operating costs, he or she might also consider that a landslide victory of their own.


Soft Drink Bottler Saves Energy With Blowers

A leading soft drink bottling manufacturer’s compressed air needs were threatening to exceed its Michigan plant’s compressed air capacity. Faced with the cost of buying a new compressor, the soft drink bottling manufacturer re-assessed their compressed air use to identify compressor and energy savings opportunities. In the audit, the soft drink bottling manufacturer identified the use of compressed air in a gap transfer as a source of compressed air and energy inefficiency.

The Ins and Outs of Vacuum Generators

There is an enormous population of vacuum generators being used successfully by industry. Applications range from pick & place to vapor extraction to bulk material handling and the number of installations is growing. Before proceeding with an installation utilizing these devices, there are two general issues to consider: efficiency and appropriateness.

Profile Dekker Vacuum

The roots of our company start with my father, Jan Dekker, who was heavily involved with oil-sealed liquid ring vacuum systems used in the gold mines of South Africa. This was in the mid-1970’s when gold prices were going up. Vacuum systems (in the mines) were optimized by improving vacuum levels using oil instead of water and by adding vacuum boosters.

Savings at the Steel Mill

This major mill complex upgraded their compressed air system and thereby eliminated \$500,000 in annual rental compressor costs, reduced annual cooling-water costs by \$500,000, and reduced electrical energy costs by \$135,000 per year.

Inappropriate-Use Assessment Saves 1,881 scfm

This factory currently spends \$735,757 annually on the electricity required to operate the compressed air system at its plant. The group of projects recommended in the system assessment will reduce these energy costs by an estimated \$364,211 (49% of current use). Estimated costs for completing the recommended projects total \$435,800. This figure represents a simple payback period of 14.4 months.

Printing Facility Vacuum System Upgrades

Most printing facilities use vacuum for one process or another.  I recently spoke with Jesse Krivolavek, (a vacuum system efficiency specialist with IVS, Inc.) about his recent adventures in the world of printing.

Chrysler Finds Vacuum Savings of $400,000 per Plant

A recent comparative vacuum technology study performed by Dr. Kingman Yee, as part of a Chrysler Summer Intern Professors Program, found that air consumption could be reduced by 98% when equipping a robot’s end-of-arm tooling with COAXÆ technology and a Vacustat™ check valve.