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FOOD & BEVERAGE OPPORTUNITIES WITH OIL-FREE


With the food and beverage (F&B) sector striving to introduce more sustainable manufacturing processes, Simon Taylor, Oil-free sales manager at CompAir, outlines two options for compressed air users: oil-free technology and heat recovery


– ten years ahead of the UK’s national target. Then, only recently, the charity WRAP, which aims to create a world where resources are sourced and used sustainably, published major new research into the greenhouse gas emissions of the UK’s food system. This showed the equivalent of 35 per cent of total emissions come from production and consumption of the country’s food and drink. To tackle this challenge, the F&B sector must de-carbonise its business operations, develop a clear understanding of emissions in the supply chain, meet commitments to zero deforestation, reduce food waste, and play its part in influencing consumer behaviours. So, where does compressed air come into


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all of this? From product filling applications and conveying, to packaging and moulding – such as for PET bottling – compressed air is a big energy user for most F&B manufacturers. With around 10 per cent of all the industrial energy consumed in Europe used to generate compressed air, it’s clear that more efficient and sustainable systems can contribute towards a greener, more sustainable future.


Contaminant-free Avoiding process contamination is a necessity for many sites. Fortunately, there are rigorous standards in place, such as ISO 8573, a group of international standards stipulating compressed air purity and quality. These govern compressed air performance and provision in environments, ensuring processes remain free from contaminants, or are at least reduced to acceptable levels, while minimising downtime and associated costs.


36 DECEMBER 2021/JANUARY 2022 | PROCESS & CONTROL


he Food and Drink Federation, which represents more than 300 companies, has set a net zero commitment for 2040


However, it’s important to note that there


are no standards or legislation that define an acceptable minimum purity level for compressed air used in F&B manufacture. Many sites, nevertheless, adopt the principles of the Hazard Analysis Critical Control Point (HACCP) to ensure facilities are complying with hygiene legislation. High-quality air can be achieved by using


oil-lubricated compressors, which rely on filtration to protect products and equipment from contamination. However, to guarantee air purity, many are switching to oil-free compressors. The latest models run more efficiently, and are better for the environment. For example, CompAir’s Ultima compressor


uses its efficient U-Drive concept to maximise compressed air production. Traditional two- stage compressors use a single motor and mechanical gearbox design to drive the low and high-pressure air-ends. In contrast, Ultima replaces the gearbox and single motor with two high-efficiency, permanent magnetic motors, allowing for performance optimisation throughout the complete volume


range. This technology offers energy efficiency savings of up to 13 per cent when compared with traditional, two-stage oil-free compressors. The motors are powered by two separate inverters, so they can be individually driven at different speeds depending on demand. An intelligent digital gearbox design then monitors and continuously adjusts the speeds of each aired, always ensuring maximum efficiency and pressure ratios. Most importantly, the compressed air it delivers is 100 per cent oil-free. Other benefits of oil-free technology include


whole life costs being reduced. Unlike oil- lubricated systems that require oil change intervals throughout their service life, there is no need to purchase equipment that would clean and separate oil from air, such as oil separators, filtration equipment and condensate treatment.


Warming up to heat recovery Heat recovery effectively enables a system to ‘recapture’ energy lost in the compression process and put it to other useful purposes. It can supplement or replace the electricity, gas or oil needed to create hot water for washrooms or process water. Alternatively, it can be transferred as direct warm air into a workspace, warehouse, loading dock or entryway. This helps cut down on energy costs, while improving the operational efficiencies of a compressor too. Naturally, a key benefit for F&B


businesses is that the recycling of by- product heat ensures that sites can also reduce their CO2 emissions. For F&B manufacturers using


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