Intelligent Control Cuts Costs
The Challenge

Par-Pak Europe Ltd is a division of  The Waddington Group, a major global packaging manufacturer, supplying retailers, packer processors and distributors. Their existing set up consisted of three compressors: two 160kW fixed speed machines and one 75kW VSD. In order to improve efficiencies on site they wanted to replace the two back-up fixed speed machines with a 160kW VSD compressor. They also required a new standalone fridge dryer sized for the whole compressor plant. Before providing a quote, Maziaks undertook a datalog of Par-Pak’s system to identify in more detail where efficiencies and improvements could be made.

 

Testimonial:

“By digging deeper and looking beyond the obvious machine changes that were needed, Maziaks have been able to offer us a more intelligent solution which has delivered both cost savings and operational efficiencies.”

Steve Betts, Operations Manager

 

Maziak's Solution

The datalog highlighted that the three compressors were all running together with no control mechanism and with considerable offloaded energy, despite a VSD compressor already in place. 
Maziaks analysed the data and recommended the purchase of an HPC DSDX302 160kW VSD, a Parker PST630 dryer and an Energair Metacentre Intelligent Control system. 

The turndown of the HPC VSD machine is 10% better than that of our competitor machines and the control philosophy ensures that offloaded energy is kept to a minimum.  The new correctly sized fridge dryer ensures the air quality to the site is consistent.

The installation of the new system was carried out with no downtime for the customer.  A large forklift was required to take the two old machines out and the ducting needed to be altered once the new machine was in place. Maziaks also upgraded the pipework to reduce the pressure drops experienced with the previous system.

 

In addition Maziaks carried out its largest ever Written Scheme ofExamination to ensure the site complies with the Pressure Systems Safety Regulations. This was completed by Maziaks’ own qualified staff.

 

Results

The new machinery and the updated system infrastructure will save Par-Pak £23,000 per annum.  They have also signed up to a Maziak 5 year Gold Service Plan and will enjoy 5 years no quibble warranty on all installed equipment plus, as a gesture of goodwill, this will extend to the old machines.

 

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