COMPRESSED AIR FEATURE
ANALYSE USAGE AND SAVE MONEY E
Energy saving improvements can often be made in compressed air. Andy Jones, MD at Mattei explains how analysing the way it is used on site is key to implementing change
nergy Savings Opportunities Scheme (ESOS) assessments carried out in the
manufacturing sector have confirmed that energy efficiency improvements can often be made in compressed air but what is the best way for factory managers to implement change and start making savings? Insight from assessments carried out among manufacturers suggests that compressed air is often an area where energy efficiency can be improved. While businesses are under no obligation
to action any of the recommendations identified during the ESOS assessment process, if a factory manager wants to take the scheme fully on board and improve their compressor efficiencies they must first analyse how compressed air is being used within the factory. This might sound obvious but many
manufacturers across the UK are operating compressed air systems without having a real grasp on what the utility is being used for and this can prove to be an expensive oversight. There is a misconception that compressed air is free once a business has invested in the equipment. In reality, the initial purchase makes up a very small part of the total lifetime costs; the main cost will always be the energy required to produce the air so in some factories there are few restrictions placed on its use. While compressed air should only ever be
used responsibly and for legitimate purposes we still see it being used to remove dust and debris from machinery, workbenches or clothes which wastes energy and causes a safety hazard. It’s often used to move goods from A to B for example to transport bulk materials in the food, construction and synthetics industries but for this task a blower can be a more efficient, cost-effective solution. A further poor practice we see is
Data logging can identify whether a
manufacturer’s production processes require a fixed speed or a variable speed compressor and whether the output is correct. The savings from such analysis can be significant; we found that one company running a 75kW compressor could fulfil its requirements with a 45kW machine with estimated savings of around £10,000 a year. Investing in a more detailed energy audit
employees neglecting to turn compressors off when the factory is closed which wastes energy; the Carbon Trust suggests an idling compressor can use around 40% of its full load power. Although some compressors consume less, it is still advisable to turn machinery off when not in use. Implementing a company training programme and an official compressed air policy outlining when and how the utility should be used should result in a positive change in employee behaviour, helping to save energy while improving safety. This doesn’t cost anything apart from time and it will be well worth it in terms of energy and carbon savings.
DATA LOGGING TO ASSESS EFFICIENCY Once employees are using compressed air appropriately it’s important to fully assess the efficiency of the system and evaluate the factory’s compressed air needs. The most straightforward way to do this is through data logging. This involves recording and measuring air consumption profiles over a seven-day period with some discussions to identify unusual patterns or planned process changes.
WHITE PAPER HELPS BOOST SYSTEM EFFICIENCY
A white paper from BOGE Compressors reveals the ways in which businesses using compressed air can save money through sensible control measures and make money by increasing output. The process of producing compressed air is notoriously inefficient with many managers overlooking the day-to-day cost associated with generating it. This white paper is designed to help manufacturing
and process firms to take control of the efficiency of their compressors and make savings in the process. Improve the efficiency of your compressed air systems covers the means to achieve these goals while maintaining the output of a compressed air system
and boosting reliability. Readers will learn about the measures available to them to enhance efficiency including effective controls, variable speed drive technology (VSD) and data monitoring. “This is one of the most in-depth compressed air
guidance documents available to industry,” says general manager Mark Whitmore. “Our hope is that with this white paper we can help businesses boost efficiency and improve reliability; that’s why it is available to everyone as a free download.”
Boge Compressors T: 01484 719921
www.boge.co.uk
According to the Carbon Trust even a small leak (just 3mm) could cost more than £700 a year in wasted energy
carried out in accordance with the international standard ISO 11011:2013 Compressed air – Energy efficiency – Assessment can paint an even more realistic picture about compressor efficiencies as can flow monitoring. Assessing leaks in the system is another
important step toward saving energy. In many companies 30% of the air generated is wasted through leaks which can prove costly over time. According to the Carbon Trust even a small leak (just 3mm) could cost more than £700 a year in wasted energy and we often see compressed air systems with 150-300 leaks. Our advice is to check for leaks frequently and carry out an annual leak detection survey. Data logging, energy audits, flow
monitoring and leak detection services are available from many compressed air companies (we recommend working with a company that is a member of BCAS as this demonstrates professionalism and competence and a commitment to health and safety and best practice) and well worth the investment. For example, the average cost of a Mattei leak detection survey is less than 10% of the overall leakage costs. Taking these initial steps should result in energy savings but investment in new equipment (if genuinely required) can pay dividends. We can cite many examples where manufacturers have saved thousands of pounds per year through updating the compressors in their factories. ESOS has already been viewed as
successful in that it’s made businesses think about energy efficiency and usage. Factory managers have an opportunity
to take the findings of ESOS assessments on board and improve compressor efficiencies; changing employee behaviour and investing in energy assessments and leak detection surveys are key first steps.
Mattei T: 01789 450577
www.mattei.co.uk
FACTORY EQUIPMENT | MARCH 2017 7
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