Feature Compressed air
VSD technology: It all makes scents
Choosing VSD compressor technology from Atlas Copco has helped International Flavours & Fragrances (IFF), a global creator of flavours and fragrances for consumer products, achieve major energy savings at its UK manufacturing plant in Haverhill, Suffolk
T
he plant is one of many IFF plants worldwide producing fragrances and flavours that are used in prod- ucts such as beverages, sweets,
dairy, savoury products, as well as fine fragrances, beauty care products, deter- gents, and household goods. As one of IFF’s European Centres of Excellence for flavour delivery systems and encapsula- tion, as well as a producer of fragrance ingredient compounds, the Haverhill plant recently underwent a significant expansion. A major part of the expan- sion was the upgrading of the plant’s Atlas Copco compressed air system. IFF is a long-standing customer of
Atlas Copco Compressors who, prior to the expansion programme, had installed an oil-free, fixed speed ZT3A together with a ZT290 machine on a service contract at the site. The com- pressors provide 100 per cent oil-free air for process instrumentation, the operation of pneumatic valves for powder transfer and plant-to-plant product conveying. Performance logging of the compres-
sors, carried out prior to the expansion highlighted the fact that significant
energy savings could be achieved with the installation of a single variable speed drive compressor to replace both existing units. The ZT160VSD was selected for its ability to match compressed output to demand in variable full load/variable load production cycles and its wide turndown range. This single compres- sor alone can provide all the air for the site while the old ZT3A has been retained as a standby unit. The100 oil-free oil-free design of the
Z machines is vital to eliminate even the slightest risk of contamination within the sensitive production envi- ronment. The ZT160VSD machine was supplied to IFF on a Service Investment Plan (SIP) contract rental arrangement that includes the Total Responsibility service provision. Not all compressed air users are able to undertake the major capital invest- ment required to take advantage of the latest technological innovations to match their current and future needs. Atlas Copco Compressors’ SIP links into its service contracts, provides free site audits, delivers new energy-effi-
cient compressors on a lease contract and requires no capital investment. Commenting on his company’s long
An international producer of fragrances and flavours is making major energy savings since adopting VSD compressor technology from Atlas Copco
Atlas Copco T: 01442 222240
www.atlascopco.com Enter 307
term relationship with Atlas Copco Compressors and the significant energy savings that have been gained through the new installation, engineer- ing manager, Matt Borrill says: “In the past year we have saved £10,000 on energy bills and significantly reduced our carbon footprint. It’s a direct result of Atlas Copco looking after our inter- ests under their Total Responsibility Plan. The plan lives up to its name. We get regular iTrak audits to monitor our compressed air use, and that means total peace of mind, plus full coverage of the unit including air ends, motor, electrical and electronic systems, cool- ers, etc with fixed annual costs for the agreed period. It means Atlas Copco technicians provide us with regular maintenance, engineering improve- ments, and breakdown repairs and machine overhauls if necessary.” He adds: “The noise-reduction char-
acteristic of the new ZT compressor is a welcome asset in view of the plant’s proximity to residential properties.”
than £30,000 in energy costs per year after switching to a CompAir L75 variable-speed compressor with heat-recovery system from Gardner Denver distributor, Rodwell Bayne. The system has been so successful that the customer has
recently invested in a second L75 RS compressor to achieve even greater energy savings. Part of the global API Technologies group, the site at
Great Yarmouth has been manufacturing sensitive, high-tech electronics since the early 1980s. Operating 24 hours a day, seven days a week, RF2M has high-demand for a reliable source of instrument air which must also be highly efficient to ensure energy consumption remains as low as possible. In 2007, the customer invested in its first CompAir L75 variable speed compressor, which was one of the first in the industry to have a heat recovery system fitted.
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Defence component manufacturer saves £30,000 in costs R
F2M Technologies, a manufacturer of electronic compo- nents for the defence-aerospace sector, is saving more
Recent analysis shows how significantly this investment
has contributed to energy savings at the Great Yarmouth site, as Rodwell Bayne director Andrew Rodwell, explains. “RF2M’s manufacturing processes require high volumes
of air and, its existing compressors had become costly to operate, due to inefficient loading. Following an air audit of the existing installation, including power cost calculations and data logging, we recommended a variable-speed compressor with heat-recovery, with an anticipated return on investment of just 14 months. “The regulated speed technology in the L75RS
produces the correct amount of air to match RF2M’s demands, helping to reduce the risk and associated costs of offload running. In the first year, the customer saved over 370,000 KWh of electricity on an average 35 per cent com- pressor consumption rate, with a high percentage of this saving attributed to the efficient, variable-speed technology.
Compair T: 01527 838200
www.compair.co.uk Enter 308
SEPTEMBER 2013 Factory Equipment
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