COMPRESSORS & COMPRESSED AIR
DYNAMIC COMPRESSOR CONTROL Ecoplant from
Ingersoll Rand delivers dynamic compressor control which helps reduce downtime and energy costs, with no capital outlay
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anufacturing plants can help reduce their downtime and boost their energy efficiency with Ecoplant – the advanced compressor controls platform from Ingersoll Rand.
Using continuous monitoring, Ecoplant adjusts compressed air systems dynamically in response to real-time demand changes. This helps to reduce energy costs and the associated carbon emissions through optimised efficiency, as well as to identify any maintenance concerns that need addressing. The simple-to-install system is compatible with all compressor technologies and designed for sites with multiple compressors using 300kW and above. It is also available
for other manufacturers’ models and can be retrofitted to existing compressed air installations.
Ecoplant monitors compressor performance dynamically, providing timely alerts on potential failure risks. As a result, maintenance issues are identified quickly and can often be resolved before they occur – reducing unplanned downtime for improved productivity.
At the same time, Ecoplant ensures ALIGNING COMPRESSOR CAPACITY WITH PLANT AIR DEMAND
lgi Equipments has announced the introduction of its compressed air stabilisation technology. The STABILISOR system aims to address the long-standing challenges of unstable compressor performance, inefficiency, and excessive wear caused by frequent load/unload cycles.
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In industrial settings, the gap between compressor capacity and plant air demand is inherently dynamic. This variability leads to frequent cut-in and cut-out operations, which destabilise the compressor and impair critical flow and kinematic components. Traditional solutions, such as increasing reservoir volume, altering cut-in/cut-out pressures, or adding variable frequency drives (VFDs), often fall short, introducing new inefficiencies or higher operational costs.
Dr. Jairam Varadaraj, Managing Director, Elgi Equipments, said: “The STABILISOR system employs a first of its kind "Recirculate and Recover" principle, seamlessly aligning compressor capacity with plant air demand through controlled recirculation and recovery techniques. By stabilising airflows within the system, the STABILISOR system minimises load/unload cycles, ensuring extended equipment lifespan, optimises energy use, achieving up to 15% energy savings in typical applications, while reducing system inefficiencies, maintaining superior performance across varying demand patterns. With its energy-efficient design and potential to reduce wear-and-tear, the STABILISOR aligns with global sustainability goals. Its implementation in industrial plants represents a shift towards greener, more cost-effective manufacturing processes.”
Dr. Venu Madhav, Director Technology, Elgi Equipments, said: “This system leverages stabilisation zones and low-pressure recovery techniques to balance airflow demands dynamically, minimise energy losses by targeting pressure points with minimal differences all while maximising overall system reliability.” The STABILISOR system will be available in two versions: • Light Version: Designed for field fitment, energy savings and enhanced reliability. • Heavy Version: Factory-fitted for superior energy savings and comprehensive stability.
www.elgi.com
pressure levels are stabilised intelligently and that only the necessary amount of electricity is used, helping operators reduce their energy consumption from compressed air generation considerably.
Keith Findlay, Technical Account Manager at Ingersoll Rand, said: “Intelligent compressed air control has been available to production sites for several years, but Ecoplant is different. Using machine learning, the system monitors 24/7 in real time and adjusts to respond to production changes. “The savings available with Ecoplant can be considerable. To take the average UK automotive plant as an example, through intelligent efficiency improvements and the reduction in production risk – plus saving time on manual maintenance – the savings can be between £217,000 and £278,000 per year on the installed compressed air estate.” To facilitate smart decision-making on the
shop floor, Ecoplant includes a customisable dashboard with real-time analytics and energy insights.
In addition, its cloud-based remote access and unlimited data logging means teams can monitor and manage performance from anywhere in the world – keeping productivity high and maintenance efficient, no matter where they are.
Findlay concluded: “Ecoplant is available as a monthly subscription including all hardware, system installation, and maintenance, so there is no capital outlay and businesses can start realising the cost savings quickly.”
To schedule a demo or find out more, visit
https://www.ingersollrand.com/en-gb/air- compressor/air-compressor-service/ ecoplant.
Ingersoll Rand
ingersollrand.com/en-gb
14 MAY 2025 | PROCESS & CONTROL
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