Group Wide Energy and Cost Savings

Group Wide Energy and Cost Savings
The Challenge

Britvic Soft Drinks Ltd were hit with a 40% increase in energy costs at six soft drinks manufacturing plants in the UK. Compressed air generation was known to be a significant energy consumer at all of these sites. Maziak Compressor Services Ltd were employed to review the three largest sites at Beckton, Rugby and Norwich and look for ways to reduce the cost to produce compressed air. Maziaks had already successfully completed substantial projects for Beckton and Norwich.

Maziak's Solution

The detailed survey work Maziaks undertook using sophisticated data collection equipment highlighted where significant energy savings could be made and a report was compiled laying out the turnkey project costs, financial paybacks, carbon saving and return on investment. The work proposed was to install Energair Retro-Fit Variable Speed Drives to five Belliss and Morcom reciprocating 40bar pressure air compressors, each with 300kw nominally rated electric motors. This is used for PET bottle blowing at all three sites, and also to one Atlas Copco GA75 75kw 7 bar air compressor used at Beckton. These opportunities were identified by Maziaks’ survey to be the projects with the best return on investment. The first turnkey installation was completed at Beckton with Rugby following a month later and Norwich a month after that. The modular design of the Energair panels make the installations very quick with the minimum of disruption to each site.

The unique selling point of the Maziak system is that the savings made are all provable after the event with in-built energy monitoring and in-house reporting. Maziaks also ensure that post-installation the equipment is optimised and tweaked to ensure maximum energy savings are continuously achieved for each site. This is facilitated through a low cost maintenance plan with Maziaks’ experienced service department and close on-site after sales care.

 

Results

Each site has shown constant and significant energy savings with a total project payback of 18 months, in line with predictions made by Maziaks.  Britvic have been delighted with the results.

The Energair Variable Speed Drive range used by Maziaks is specifically designed for air compressors and is available in sizes from 4kw to 315kw as standard product.

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