Case Studies

Energy Saving Case Study

Industry: Soft Drink Manufacturer
Product: 40 bar Air Treatment
Project Objective: Energy Savings & Air Quality Improvement

PET Bottle Blowing Energy Savings - Over 50K Per Annum

The old installation comprised of five oil free Bellis and Morcom piston compressors ranging from 300 to 550kW and water cooled Denco air treatment equipment. Energy costs were rising hugely and the old plant could not achieve the air quality needs of a new SIG bottle blowing plant.

Maziak Compressor Services Ltd designed, built and implemented a new installation comprising new starter control gear for the reutilised existing compressors, new stainless steel manifold pipework, new air treatment plant and new galvanised wet and dry receivers. The predicted air quality and energy management of the whole system is overseen by the Maziak installed "EnergAir" control package with remote PC visualisation and alarm monitoring. This has continually validated energy savings of over 50K per annum.

New Install Case Study

Industry: Food Preparation
Product: 11kW Unigy TAS Compressors
Project Objective: Installation of new energy efficient compressed air plant

The customer required a new compressed air plant installation after their aged Atlas Copco compressor become unreliable.

After a Datalog was carried out and analysed it was found that there was a large difference between their day time and night time usage. Two new Ingersoll Rand 11kW TAS Unigy Compressors were installed giving variable compressed air delivery to cater for both running periods. This meant that during the day shift both compressors would run but during the night shift one would shut down and the other compressor would run at 50% maximum loading. The compressor with its integrated dryer and filtration achieved an ISO air quality of class 2.4.2 which met the customer's air quality issues.

New Install Case Study

Industry: Electronic Manufacturing
Product: Flexible Active-Matrix Display
Project Objective: Installation of new energy efficient Nitrogen Generation Plant

The customer was not happy constantly purchasing liquid Nitrogen from a supplier due to costs and delivery reliability. After a site visit was carried out by Maziak Compressor Services Ltd and information gathered we were able to offer a complete Nitrogen Container Package. This package was driven by two new Ingersoll Rand 11kW Unigy Compressors along with a dryer and air treatment package and gave a variable compressed air delivery of between 0 to 120cfm 24hrs a day 7 days a week. A State of the art Nitrogen Generator was installed into the package which will allow for a constant supply of Nitrogen 24 hrs a day 365 days per year at 99.95% purity (this is what the customer required). This package contained all air treatment, air storage, Nitrogen storage, ventilation, heating and even its own local distribution board (a complete plug and play solution). This meant an installation time onsite of only 8 hrs. This Nitrogen container has a payback time of only 9 months and has cut their Nitrogen spending by 75% per year.

New Install Case Study

Industry: Food Preparation
Product: Iceberg Lettuce
Project Objective: Installation of new energy efficient compressed air plant

The customer required a new compressed air plant installation for their new state of the art production facility. After a site visit was carried out and information gathered two new Ingersoll Rand 11kW Unigy Compressors along with a dryer and air treatment package were installed giving a variable compressed air delivery of between 0 to 120cfm 24hrs a day 7 days a week. An achieved ISO air quality of class 2.4.2 was also met which covered the customer's important air quality issues. The pipework distribution network was installed entirely in Ingersoll Rand Simplair; this aluminium pipework gives highly efficient air delivery and potential for simple future expansion.

Upgrade Case Study

Industry: Pharmaceutical Manufacturer
Product: Unigy & Air Quality
Project Objective: Upgrade of Compressed Air Quality - Oil Free Air From Oil Lubricated Compressors.

The compressed air plant was becoming unreliable and the compressed air quality sub-standard for the nature of their industry.

Maziak Compressor Services Ltd were contacted to technically advise, design and build a compressed air package to suit the needs of a world class pharmaceutical manufacturer.

The variable speed drive lead/standby Ingersoll-Rand Unigy compressor plant met their energy efficiency requirements with a sophisticated air treatment package to meet the pharmaceutical air quality to the standard of ISO8573.1 Class 2.2.1

This system permanently monitors all aspects of air quality for continual validation. With this installation oil free air from oil lubricated compressors is proven, continually and with energy efficiency.

Upgrade Case Study

Industry: Newspapers & Magazines
Product: Intelliflow, Control
Project Objective: Reduce energy costs, improve system reliablity

The new compressor installation was completed in 2004 by Atlas Copco Compressors Ltd.

Although thought was given to energy efficiency with the installation of one 180kw variable speed drive compressor with the other three 160kw fixed speed machines and an Atlas Copco control system it became apparent to the site that the operation was still not right. Our initial survey found annual energy costs of £250,100 to run the compressors with problems of over-pressurisation, fluctuating system pressure and high maintenance costs.

We have installed an Ingersoll Rand Intelliflow modulating pressure control valve to stabilise the distribution pressure to the site and give the benefit of utilising dry storage capacitance to reduce energy cost. This has allowed the site to reduce the distribution air pressure from 9bar down to 7.7bar without compromising the generation or air treatment pressure. The pressure reduction minimises leakage and false demand and therefore reduces compressor loading.

Removing the Atlas Copco compressor control system and replacing it with an intelligent Energair Metacentre air compressor control package gave the added energy savings from improving utilisation of the variable speed driven compressor while still using the base load fixed speed machines and rotating them for duty cycle. The whole installation was completed under turn-key contract by Maziak Compressor Services Ltd. Following the completion of all works both Maziak and the site conducted a study to validate the improvements made, both parties agreeing independently that an annual energy saving of £116,300 has been achieved. Other benefits include a 2% improvement in reactive power usage, meaning additional levies from their energy supplier of £3,000 to £4,000 per month are avoided; and reduced compressor maintenance costs.