Industrial Utility Efficiency

System Assessments

Analysis of the pressure data logging showed that, while the variable speed drive compressor maintained a constant discharge pressure near 120 psi, the pressure at various critical points fell to as low as 85 psi during peak production operations. General pressure in the plants, especially Plant 2, fluctuated between 102 and 112 psi, showing that the pressure/flow control valve was not regulating properly, and that Plant 2 lacked enough general storage volume to support transient flows.  

The Gentex Journey to Reliable Energy Conservation - 3 Levels of Compressed Air Systems

The information contained in this article, will help the operator to assess his/her systems, and identify where these systems fall within a three-level category. There are many ways, and opportunities to make a compressed air system produce reliable and good quality air. The three levels discussed here could also be characterized as a “continuous improvement plan” which can be achieved over the course of time, and with the occasional investment of money.

Compressed Air Dryer Key Performance Indicators

The purpose of this article is to point out the key performance indicators (KPI’s) that can assist in maintaining the performance and troubleshooting of compressed air dryers. The most important KPI to monitor is the pressure dew point (PDP) of the compressed air exiting the dryer(s). The PDP of the compressed air should be monitored at the discharge of each dryer and downstream of where the compressed air from multiple dryers converges. 

When Mixing is the Goal, Why Would You Aerate? Compressed Gas Mixing Provides an Alternative Approach

At the beginning of the 20th century, biological wastewater treatment — more specifically, the activated sludge process — was developed and became widely accepted as the treatment method for municipal wastewater, helping to protect our lakes and rivers from pollutants and support public health. In 1947, the Committee on Development of Uniform Standards for Sewage Works was created by the group known as the Great Lakes – Upper Mississippi River Board of State and Provincial Public Health and Environment Managers. 

Nitrogen Characteristics and Benefits of On-Site Generation

Modified Atmosphere Packaging (MAP) accounts for a significant amount of nitrogen usage in the food and beverage industry. MAP involves injecting nitrogen into beverage or food packaging to purge and displace any oxygen-containing air with nitrogen. Oxidation of lipids in food products causes rancidity. Since oxygen is replaced with dry, inert nitrogen in MAP packaging, no product oxidation will occur. The result is maximized product shelf life. 

Achieving “Technically Oil-Free” Compressed Air

In this article we will discuss how to achieve actual oil-free air from your air compressor, no matter what type of air compressor it is. Air compressors of all designs turn mechanical power into pneumatic power by successively concentrating air across compression stages. A rotary screw air compressor, for example, utilizes rotating helical screws to drive air forward, increasing its pressure by reducing the volume of space the air mass takes up. Mechanical compression of this nature takes quite the force and energy to accomplish, which equates to heat generation and physical wear inside of the compressor. 

Safe and Efficient Compressed Air Nozzle Food Applications

There are a tremendous variety of unique and creative ways people in the food industry have overcome their need for compressed air blowoffs used for cleaning, drying, cooling, conveying and overall processing. You may have seen some of them yourself. It is not uncommon to view open copper tubes, pipes with a crushed end, plugs or caps with holes drilled into them, modular flex coolant lines or nozzles designed for liquid application but blowing air.

Efficiently Controlling Huge Flow Variations in Sandblasting Compressed Air System

Most industrial systems like compressed air have essentially random demand if you look at the long-term life cycle of the system. Hundreds, even thousands of independent small and large subsystems require constant or varying flow. These demands are typically not timed or synchronized with each other, so they aggregate to a fairly random flow profile, within a range. That range changes significantly when production processes change. Certainly a 2-week audit might show some patterns that appear predictable for demand A (“production”) and demand B (“non-production”) or day type, but they change over time as the plant adapts to new production systems and removes old ones. If demand was that profile forever, a lesser experienced auditor might be tempted to size one set of compressors that work perfectly for that profile but not for alternates.

Wonderful Pistachios & Almonds™ Optimizes Piping and Air Compressor Automation

The Wonderful Pistachios and Almonds campus in Lost Hills, California is a manufacturing facility that processes and packages pistachios and almonds for the consumer market. Food processing requires extensive use of compressed air to control multiple applications ranging from actuators, valves, optical sorters, packaging equipment and plant maintenance operations. The campus has its peak season during harvest in late August/early September, but processing and packaging operations take place year-round.

Are My Pulse Jet Dust Collectors Wasting Compressed Air?

Pulse jet dust collectors are common air/material separators in the food industry serving as dust collectors, bin vents, and pneumatic conveying filter/receivers.  The biggest complaint I’ve heard from plant managers and plant engineers about these is that “these collectors don’t make us any money”.  While that is true, they can COST a plant a significant amount of money if they aren’t maintained.  Wasted compressed air is one of the worst offenders, as it not only costs the plant in energy costs associated with creating and conditioning the air, but also in premature bag failure from improper cleaning, production downtime, and inefficient dust collection leading to increased housekeeping requirements, and other many issues.

Compressor Controls

As part of its ongoing corporate initiative to find ways to reduce its energy bills, and the costly

Piping Storage

Since completion of the system upgrade in the fall of 2020, PC Forge is on track to save an average

End Uses

The purpose of this article is to show there isn’t always a proportionally linear relationship

Pressure

Most industrial systems like compressed air have essentially random demand if you look at the long-

Air Treatment/N2

Just as many ambient air issues with regard to the actual equipment operating environment are

Leaks

One of the best ways to reduce compressed air costs is to look for ways to reduce leakage flow, an

Pneumatics

Sustainability is a high priority for today’s consumer packaged goods (CPG) companies. Driven by

Vacuum/Blowers

Operating the vacuum system at higher levels (then necessary) affects the needed volumetric flow to