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.  

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.

Dust Collector Pilot Program Points to 16 GWh of Energy Savings at Imerys Minerals Processing Facilities

For Imerys S.A. there’s little question about the importance of managing dust collection systems it uses to control and reduce harmful particulates in its worldwide minerals processing facilities. And now there’s zero doubt about the tremendous energy savings it stands to save by reducing the amount of compressed air needed for these same dust collectors.

Troubleshooting Heatless Desiccant Dryer Proves Challenging Yet Successful

One of the most satisfying parts of being a compressed air system auditor is resolving compressed air system reliability issues. This article exposes a seldom, if ever, mentioned problem that can occur when air dryers are dedicated to air compressors. It examines a real-world application and discusses the action taken to remedy the situation.

Three Real-World Applications for Pneumatics and IIoT

Industrial operations and manufacturers using pneumatics have access to more Industrial Internet of Things (IIoT) technology than ever before, from position sensors on cylinders to system flow sensors and edge gateways that operate independently from the machine controller with globally accepted communication protocols.

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.

Smart Monitoring: The Power Behind Pneumatics Productivity

In manufacturing and packaging facilities that rely on pneumatics, there’s a four-letter word worse than virtually any other: leak. Unidentified air leakage and unexpected maintenance in pneumatic systems are significant sources of revenue and productivity loss but identifying the cause of leakages and preventing unforeseen downtime is typically a challenge.

Nitrogen Generation System Helps Death Wish Coffee Gain Production Efficiencies

As founding members of a startup company in the compressed air and gas purification and separation industry, nano-purification solutions felt a kinship with the owners, employees and mission of Death Wish Coffee Co. The kinship and nano-purification solutions’ expertise in onsite nitrogen generation led to the installation of a nitrogen generation system that contributes to the overall efficiencies and operational costs savings at the coffee roaster’s production operation in Round Lake, New York.

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.

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