Technology

Compressed Air Best Practices® Magazine interviewed Mr. Bill Kennedy, Global Marketing Manager, Mattei Compressors.

If the electricity costs 8x what you paid to purchase the compressor, and you can reduce that value by 20% or more, the compressor is virtually free as the energy savings provide a return-on-investment that exceeds the purchase price. Now, if you eliminate the need to ever have to overhaul the airend you gain a massive financial and long-term reliability advantage.

Utilities monitoring paired with machine learning models can reliably predict anomalies, prompting action that can prevent waste and optimize resource use. 

If there was ever a place where manufacturers can save energy using compressed air and make measurable gains toward sustainability, it’s with pneumatics that power a seemingly infinite variety of machines and processes.

The history of Festo began in 1925 in Germany. Festo USA was founded on March 15th, 1972 in Port Washington on Long Island, with the focus of being a full-line supplier of pneumatics – a focus we continue with today.

During Dealer Week, they needed enough compressed air to power multiple machines at a time all day long. Keeping simultaneous demos running for all their top machines required airflow of up to 400 cubic feet per minute (CFM). However, outside of Dealer Week, their compressed air demands were quite modest. On a typical day, they only needed 20 CFM to power their dust collection system and pneumatic tools for their dock and warehouse crating areas. 

In early October 2022, professionals from around the world gathered at the Best Practices 2022 EXPO & Conference in Atlanta to source and learn about the latest on-site utilities powering modern plant automation including compressed air, blowers, vacuum, pneumatics, motors and cooling water systems. This report recaps a fraction of the event’s education curriculum and provides an editorial tour of sponsoring exhibitors’ machinery displays and product introductions.

The U.S. air compressor market has a compressed air installed base of at least 15 million horsepower. Further, it evaluated various air audits across different customer types, sizes and segments and determined U.S. manufacturers stand to save around 13 billion kilowatt hours (kWh) annually in electricity associated with compressed air. That translates to a savings of $1 billion in energy costs per year, which would remove nine million metric tons of CO2 annually. That equates to more annual energy usage of more than 1 million homes in the United States.

Headquartered in Noblesville, Indiana, SMC Corporation of America has grown exponentially since the company began operations in the United States in 1977. Today, the Noblesville campus occupies 345 acres and encompasses 2.6 million square feet of manufacturing and warehouse space. 

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. 

Compressed air is used in all the company’s plants and is often the single largest energy end use within them. As a result, compressed air energy-saving measures are often replicable across the company and offer significant positive impacts. One area of focus is with compressed air leaks since they are “the best low hanging fruit to focus on and they always keep popping up and waste energy”.