COMPRESSORS & COMPRESSED AIR
Using the latest freely available software, and thoroughly reviewing compressed air consumption through an energy audit, are two places to start your energy efficiency journey
savings can be made. Energy audits are vital in optimising
efficiency as they fully assess the compressed air system performance throughout a machine. An audit can flag areas where compressed air is being wasted or lost entirely. Between 5–35% of compressed air in a system can typically be lost to leakage, so leak prevention is important.
EFFICIENCY IS BETTER BY DESIGN
Improving energy efficiency in manufacturing can reduce costs, boost productivity, and support sustainability goals, says Steve Sands, Technical Consultant at Festo
ccording to the UK Government’s ‘Energy Efficiency in the Manufacturing Sector’ report, energy costs represent 5% of a manufacturer’s total costs — around £1.5m for companies with more than 250 employees. Improving energy efficiencies can therefore significantly reduce costs and increase profitability. Even a small percentage gain in energy efficiency can result in thousands of pounds worth of savings. Energy-saving measures can also help manufacturers reap environmental benefits and productivity gains. Energy efficiency can be optimised in several ways, from considering the machines used in a process to investing in building improvements and implementing behavioural and cultural changes. One area where gains are often made is in the compressed air system of machines. Optimising the energy efficiency of these machines from the outset should be a key consideration for original equipment manufacturers (OEMs) and can be achieved by reviewing the design. The use of online systems and energy audits is proving vital in this regard. Over-specification is a common mistake in pneumatic systems. Online assessment tools make it quicker for manufacturers to identify the best components for their application and refine their design, delivering both CAPEX and OPEX savings. For example, tailoring the size of pneumatic drives by just one size to more precisely fit requirements can save up to 40% of an application’s air consumption. Evaluation matrices, cost calculators and simulation software, plus tools such as pneumatic simulation and sizing, make it easy for engineers to optimise air systems for their
A 14 FEBRUARY 2025 | PROCESS & CONTROL
specific applications. Additionally, online catalogues allow engineers to quickly find the energy saving benefits of products such as entry-level pulse valves, vacuum generators and totalling flow meters, as well as intelligent smart products.
Packaging machinery specialist Cerulean found online tools invaluable when it wanted to redesign its highly successful FPS-1 tube packer. The aim was to make the machine more energy efficient and achieve reduced cost of ownership. Cerulean wanted to design the new tube packing machine — the FPS120s — for hygienic packing at speeds of up to 120 tubes per minute. Festo worked with Cerulean to achieve the most energy efficient design. Festo conducted a comprehensive review of every element of the machine (from component selection to running costs at designated outputs) and applied its pneumatic simulation and sizing tools. Festo’s Pneumatic Simulation Tool allows users to input specific application parameters, such as the number of cycles per minute requirement, tube diameter/length, and so on. The tool then identifies the optimum pneumatic cylinders, flow controls, valves, and settings based on energy consumption to deliver the most efficient options. The Pneumatic Sizing Tool can then be used to refine the system design. This online tool addresses aspects such as positioning time and CO2 emissions. Crucially, it gave Cerulean confidence that all the pneumatic cylinders and valves specified for the new FPS120s were correct for the application. By selecting the right technology and optimally sizing components, long-term energy
To be most effective, an audit should follow the ISO 11011:2013 approach, which outlines requirements for conducting and reporting the results of a compressed air system assessment. The International Standard explains how engineers should analyse the data, document the findings, and estimate the amount of energy that can be saved. Festo conducted such an energy audit for Cerulean. Festo experts assessed the existing FPS-1 packing machine using a mobile measuring device to measure actual flow and pressure values. Festo installed the measuring equipment on the main air supply from the compressor to the machine and took readings to compare the machine’s maximum and average air consumption. These conditions were repeated for the prototype FPS120s. Each test result was recorded over the same duration, with machine cycles taken into consideration. Both machines were pressure regulated to approximately 4–5 bar. The results proved that the FPS120s tube packer offers significant efficiency and TCO improvements over the old FPS-1 model. It delivers a 48% improvement on maximum air consumption and an impressive 92% improvement on average air consumption. Energy audits are not limited to individual machines. They can also be carried out to ascertain the compressed air system performance across a whole factory, from the point of generation in the compressor room to consumption on the production line and all points in between. The number and type of compressors, the required operating pressures, and the number of filters and dryers required all influence energy efficiency. Carrying out audits in compliance with ISO 11011:2013 ensures a consistent approach and produces comparable results across multiple sites, so improvements can be made company-wide.
Since working with Festo, Cerulean has calculated a saving of 4.5 million litres of compressed air per year, based on the FPS120s machine running 24/7, 365 days a year and excluding any downtime.
Festo
www.festo.com/energysaving
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