Case Studies

We have extensive experience across multiple industries and all imaginable compressed air and pipework systems.

Compressed air is not free and there are many ways beyond the regular maintenance of your equipment to reduce energy and costs. Maziaks has helped many clients to identify remedial and proactive actions which often cost very little or nothing to implement and which has lead to huge energy and cost savings. We have always focused on tailored solutions for our customers and in doing so we have been at the forefront of a number of innovations in the UK compressed air and associated industries.

Read some of our case studies below to see what we are capable of and how we might help you.

We've got the power to reduce Nitrogen Gas costs
The Challenge

With the significant increase in costs of solder manufacturing due to raw materials, electronics makers have looked for solutions that save cost by reducing the dross. One such method is the implementation of a wave soldering system using inert gas. The inert wave soldering system shows significant dross reduction and its wettability is better than conventional systems. 
The inert gas utilised is high purity Nitrogen (N2). The power management company who were buying in the gas in high pressure cylinders were looking for AN EVEN BETTER SOLUTION.

Air kisses and the show goes on
The Challenge

In 1983 Maziak had installed four Broomwade machines and over 20 years on, despite careful maintenance, these were ready for an upgrade. 

Getting a SLICE of the Action
The Challenge

Attracted by the services Maziak were showcasing at the FoodEx Show, a leading dessert producer wanted to discuss significant projected expansion needs alongside some critical issues with their existing compressed air system.

PET Keg Production Expands Into The UK
The Challenge

Maziak’s core values and previous PET blow moulding experience at major blue-chip companies (Britvic and Princes) made us an attractive partner to deliver the compressed air system and deal with the complexity of the works required.

More Air - More Reliability - More Control - Less Cost
The Challenge

A longstanding customer of Maziak, were looking to have a complete overhaul of their plant room.

Quality AND Size Matter—Small but Crucial Role
The Challenge

Kitting out 528,000 ft2 of warehouse space is no mean feat. 

Nitrogen Generation is taking off
The Challenge

Maziak were commissioned to design and install a dedicated Nitrogen Generation system to supply the tyre overhaul workshop as part of this major development. 

Hopping Along Nicely
The Challenge

To ensure the highest product quality and prolong shelf-life, the company uses a process called gas flushing which requires nitrogen gas. Intrigued by the nitrogen generation cost saving information Maziak were promoting at a PPMA Show, they wanted to explore how they might benefit and reduce the high costs of multi-cylinder nitrogen packs.

Buying Bulk? Let the new Generation take over
The Challenge

Attracted by the possible cost and environmental savings Maziak were showcasing at the PPMA show in 2016, they wanted to explore how they might reduce their reliance on expensive bulk liquid gas.

Out with the old, In with the new = energy & service savings
The Challenge

With well over 20 successful years of operation fulfilled, the compressor equipment, which included HPC ASD, BSB and CSB compressors, was ready to be replaced.

Seamlessly Advancing Design & Technology
The Challenge

The entire system, from the compressor through the pipework, to the final drops, had to be energy efficient, to reflect the school’s ethos of waste reduction and improvement through better technology. The pipework installation work was to take place during term time presenting additional challenges.

Long-term Loyalty and Partnership - Cradle to Grave!
The Challenge

With all the service history and compressor usage statistics documented within Maziak’s Service Management Software, Maziak had all the data they needed at their fingertips to recommend the right new machine.

Collaborative Partnership Ensures Reliability and Fosters Trust
The Challenge

The key for the OU is reliability of equipment and as their trusted partner for compressed air, it falls to Maziak to deliver on this. With 14 air compressors—a mixture of piston and screw of varying brands and ages—this is a critical area .

The 'Appeel' Of Cutting Costs, Increasing Flexibility and Enhancing H&S
The Challenge

Fruitapeel’s interest was sparked in the benefits of nitrogen generation in lieu of cylinders. Discussions ensued around the possibility of generating nitrogen on site and doing away with the costly cylinders at its Llantrisant site in South Wales.

An expert brew of improved energy, efficiency and reliability
The Challenge

Maziak have supplied and serviced the compressed air system on site for over 15 years forging a strong relationship. Over the years a number of data-logs have been conducted to uncover ways to improve efficiency and reliability whilst saving energy and costs. 

Concealed Compressor & Pristine Pipework
The Challenge

The main focus of the project was to provide compressed air facilities, to hide pipework and to create a solution for locating the compressor in a convenient but unobtrusive way.

Precision Power, Quality and Experience Matched
The Challenge

An existing HPC user for 20 Years they were keen to stick with the advanced technology and reliability of the product when updating their equipment

Consider the Alternative - Would Rental Suit Your Needs Better?
The Challenge

They have based their business model around quality, cost and delivery.To uphold these principles and meet their increased demand, they needed a larger and more reliable compressor.

 

Cut Through the Norm to Deliver Efficiencies
The Challenge

Their operations use CO2 lasers for cutting the steels and metals and the industry norm had been to use N2 in the beam guide due to two key qualities—it is moisture and CO2 free.  Molecules of either of these would weaken the beam by diverging it.  Maziak, however, through its partnership with Parker were able to offer an alternative solution at much reduced cost. 

A Challenging Pipework Configuration & Precision Cooling
The Challenge

Expansion has led to a new factory in Dunstable, requiring compressed air, pipework and a chiller. Despite the factory being empty there were some significant challenges with 34m x 24m  block pillars every 6 metres and only 7 days to complete what would normally take up to a fortnight.

Innovation for Innovators
The Challenge

Their extensive Research & Development activities included a project to create a mobile treatment plant using nitrogen bottles within an articulated trailer. GE’s Peterborough branch were already a Maziak customer and when we were made aware of these plans, we offered an alternative solution to nitrogen bottles.

High Street Retailer Chooses Maziaks for Major Project Works
The Challenge

 The warehouse contains a great deal of automation for storage and conveyors and the challenge was to provide an extensive compressed air network to deliver the pneumatic power required over three chambers and five floors.

Large Volumes & Extreme Reliability are Keys to Success
The Challenge

A major UK energy provider had taken over an old wind turbine manufacturing facility and were updating the site with a new paint and preparation building.The challenge was to provide large volumes of compressed air to a blasting operation. 

Airbox Plug & Play Solutions - Air and Nitrogen
The Challenge

The customer was not happy constantly purchasing liquid Nitrogen from a supplier due to costs and delivery reliability.

Group Wide Energy and Cost Savings
The Challenge

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.

Reduced Costs & Improved Efficiency: Substantial & Substantiated
The Challenge

Part of the site’s remit for investment was to reduce cost and improve efficiency.  Maziaks’ track record of reducing energy costs for other soft drinks manufacturers led to an invite to survey their site and propose a plan.

Oil Free Air from Oil Lubricated Compressors
The Challenge

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.

Airbox - Plug & Play Solutions
The Challenge

Our client, a waste management company, provides a range of cost and environmentally effective processing, recycling, disposal and energy recovery services for local authority and private commercial customers. They need to deliver a clean, constant compressed air supply to the pumps at the heart of their landfill site to allow for the waste liquid (leachate) caused by the decomposing of the waste to be removed and stored.

Energy Efficient Control
The Challenge

The compressor house had to move to accommodate additional production machinery with substantial extra air demand anticipated for this busy 24/7 food factory.

Energy Savings following Datalog Survey
The Challenge

Premier Foods had datalogged and recorded their previous compressors and found their benchmark to work from. The problem was, how to prove the savings were actually in line with predictions, and how to continually prove further savings as the factory changes.

Intelligent Compressed Air Management
The Challenge

The standard control configuration meant that the variable speed compressor (180kW) was always the lead unit.  During times of low demand, this could adjust its flow rate and energy consumption effectively, but as demand rose and the other compressors (3 x 160kW fixed speed) were switched on, control efficiency was substantially reduced.

Make Energy Savings & Rental Work for Your Company
The Challenge

When they approached Maziaks, they were running a fixed speed Atlas Copco 45kW compressor which was massively oversized for the site and which had led to significant energy wastage at a high cost to the company.

Relationship & Quality Product = Trust
The Challenge

Our challenge was to reduce energy costs without compromising the need for increased capacity. Our solution also needed to be able to handle a variety of air demand conditions and fast changes in demand as blowmoulders come in and out of production.

Self Contained Compressor System with Minimal Install Time
The Challenge

Air Products required a standalone compressed air system to drive their decanting system at Didcot Power Station. This needed to be self-contained with all electrical requirements, cold weather protection and ducting.

Nitrogen Generation Beats Bulk Storage Option
The Challenge

Maziaks have supplied and serviced Wells and Young's compressed air system for over 7 years and following the largest ever nitrogen generator installation in Europe at Rohm and Haas (UK) Ltd we talked to Wells and Young's about the benefits of replacing their bulk liquid nitrogen with their own generation equipment.

The Right Investment = Big Energy & Cost Savings
The Challenge

Maziaks’ innovative and proactive approach impressed Nampak.  We highlighted key areas where significant savings and improvements could be achieved from very little capital expenditure.

Cost Effective and Compliant
The Challenge

In partnership with Maziaks, they have managed not only to increase air efficiency but have also improved air quality to back up their Hazard Analysis and Critical Control Points (HACCP) criteria.

N2 Airbox Replaces Bulk Storage & Eases Expansion
The Challenge

Production at the Frome site requires significant volumes of nitrogen and the customer was looking for an alternative to purchasing liquid Nitrogen from a supplier, due to costs and delivery reliability.

Energy Savings & Air Quality Improvement
The Challenge

Energy costs were rising hugely and the old plant could not achieve the air quality needs of the soft drinks industry.

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