search.noResults

search.searching

dataCollection.invalidEmail
note.createNoteMessage

search.noResults

search.searching

orderForm.title

orderForm.productCode
orderForm.description
orderForm.quantity
orderForm.itemPrice
orderForm.price
orderForm.totalPrice
orderForm.deliveryDetails.billingAddress
orderForm.deliveryDetails.deliveryAddress
orderForm.noItems
FEATURE COMPRESSED AIR


CENTRALISED VACUUM SYSTEM REDUCES ENERGY USE BY 40%


David Smith St Ives is a leading UK manufacturer of high performance engineered timber products whose output is totally dependent upon an uninterrupted supply of plant air and vacuum. By replacing ageing stand-alone units with a centralised rotary screw VSD vacuum pump system from Atlas Copco’s distributor, Anglian Compressors, production continuity has been assured and 40 per cent savings in energy costs realised


E


stablished in 1963, the family-owned and managed business occupies a


purpose built 165,000 sq ft manufacturing plant on the outskirts of St Ives, Cambridge. From there the company utilises modern production techniques, together with traditional craftsmanship to produce a range of high quality bespoke staircases, roof trusses, engineered joists, Glulam and door-sets. The company’s precision manufacturing


capabilities enable it to fulfil large commercial orders as well as offer one- off bespoke products for house builders, housing associations and commercial contractors. Product development frequently involves working in both public and private sector projects alongside architects, structural engineers, surveyors, and specialist contractors. Each product division has its own design


team, using the latest CAD software to prepare technical drawings and product specifications. These designs are then programmed directly into specialist machinery to produce each component. Five-axis CNC routers are key production


units in the manufacturing process cycle and rely on vacuum to clamp and unclamp work pieces. Before the centralised vacuum system was installed, the company had operated over the past twenty years with a system of eight vane- type vacuum pumps, two feeding each of the four CNC machining centres. The system of allocating a 5kW pump and a standby unit at the point of use to each machining centre was not the ideal solution to prevent the risk of downtime, as the company experienced when two pumps broke down in close succession. The incident was the catalyst that


prompted an investigation into the potential advantages offered by deploying a centralised system based on


12 APRIL 2018 | FACTORY EQUIPMENT


Centralised Atlas Copco vacuum system reduces energy consumption by 40 per cent for David Smith St Ives


INSET: David Smith St. Ives’ tools use vacuum air to transfer its products to and from different machines


the latest developments in rotary screw vacuum pump technology. Consequently, Peterborough-based Atlas Copco premier distributor, Anglian Compressors, who earlier had supplied the company’s GA air compressor, was called upon for recommendations. Anglian undertook an air system audit


and in-depth investigation into David Smith St Ives’ production processes to see how compressed air and vacuum were utilised; with a view to improving energy efficiency and equipment reliability as well as reducing service costs. Their recommendation was a centralised rotary screw VSD vacuum pump system. Rotary screw vacuum pumps are based


on proven compressor screw technology and provide significantly higher performance levels and reduced maintenance, noise and heat emissions compared to conventional oil-sealed and dry vane vacuum pumps. With the application of variable speed drive, it’s possible to tailor vacuum production to precisely meet process demand, as the new system installed by Anglian Compressors clearly demonstrated. An Atlas Copco GHS 900 VSD+ 15kW,


oil-sealed rotary screw vacuum pump, that offered a nominal displacement of 870m3


/hr (510 cfm) and an ultimate


pressure of 0.35 mbar(a), was installed. This was on the basis that if the promised performance, in terms of load capacity and energy savings, was not achieved during the first month of operation it would be removed without penalty or further commitment The GHS VSD+ pump was connected to a new ring main installed by the customer and to all concerned the performance results were impressive.


Whereas the former eight stand-alone pumps were each individually demanding 5kW shaft power 100 per cent of the time, regardless of fluctuating operational demand, the new, complete 15kW system with VSD was coping at only a 60 per cent load for 97 per cent of the time throughout a 68-hour production week. The net result was a 40 per cent reduction in energy demand. Simon Wadsworth, director at David


Smith St. Ives, was both surprised and delighted with the centralised system’s performance, commenting: “To be honest, I was sceptical when Anglian claimed this degree of power savings. I was aware that VSD reduced energy demand as virtually all of our other equipment has had inverter drives fitted for the past ten years, but the GHS now gives us a 40 per cent capacity margin for more demanding applications and the ability to cope with any future expansion opportunities.” He also welcomed the ability to monitor system performance daily on his desktop computer from the unit’s Elektronikon controller data feedback As for the redundant standby rotary vane units, they are now linked into the system as back up for critical equipment during scheduled service periods provided under the five-year Atlas Copco Total Responsibility maintenance contract. The final comments from Simon


Wadsworth: “Not only have we made a sound investment with payback in terms of reliability, support, and trouble-free productivity, we have also built a great relationship with Atlas Copco and Anglian Compressors.”


Atlas Copco www.atlascopco.co.uk/compressorsuk T: 0800 181085


/ FACTORYEQUIPMENT


Page 1  |  Page 2  |  Page 3  |  Page 4  |  Page 5  |  Page 6  |  Page 7  |  Page 8  |  Page 9  |  Page 10  |  Page 11  |  Page 12  |  Page 13  |  Page 14  |  Page 15  |  Page 16  |  Page 17  |  Page 18  |  Page 19  |  Page 20  |  Page 21  |  Page 22  |  Page 23  |  Page 24  |  Page 25  |  Page 26  |  Page 27  |  Page 28  |  Page 29  |  Page 30  |  Page 31  |  Page 32  |  Page 33  |  Page 34  |  Page 35  |  Page 36  |  Page 37  |  Page 38  |  Page 39  |  Page 40  |  Page 41  |  Page 42  |  Page 43  |  Page 44