An automotive parts manufacturer upgraded their system to produce a more efficient supply of compressed air. Data logging of the old system showed that the compressed air system was consuming power at a rate of over 30 kW per 100 cfm produced. With new upgrades, the system is now running around 21 kW per 100 cfm, an improvement of about 30%.
Improvements included the following:
- Variable speed drive compressor,
- Cycling air dryer,
- Low loss filters,
- Airless condensate drains,
- Properly sized piping,
- Leakage repair, and
- Installation of a remote monitoring system.
Like many automotive suppliers, this plant was shut down due to Covid-19, with no production demand. The Plant Environmental team lead, while working at home used the monitoring system to check how the system was doing and notice it was left running for no reason, where the system should have been shut down.
Estimated consumption for the running system, which was supplying only leaks, was about 12,000 kWh per week costing about $2,000 in electricity. Once the compressors were correctly shut down the consumption dropped to a total of 800 kWh for the entire month of April. At this rate, the monitoring system will have quickly paid for itself by the corrective action it has inspired. This system will work on after the shutdown is over, ensuring that the system remains efficient and that leak levels are minimized. This is an excellent tool to use to minimize compressed air costs!
Filed Under: Pneumatic Tips