Test & Measurement
Air leaks lead to profits vanishing into thin air
By Javier Irazola, Fluke Corporation C
ompressed air is the food and beverage industry’s clean and accessible “fourth utility” after the big three of water, electricity and natural gas. The reliability of this fourth utility depends on predictable air pressure, which means even small leaks can come at a high price.
According to the Compressed Air & Gas Handbook Seventh Edition published by the Compressed Air & Gas Institute (CAGI), “A single ¼-inch leak in a compressed air line can cost a facility from $2,500 to more than $8,000 per year. Locating and fixing leaks will result in significant savings depending on pressure requirements and energy costs.” Portable sonic industrial imaging technology adds a visual component to traditional compressed air leak detection best practices for easier detection and fixing of air leaks. Here’s a look at air leaks commonly found in the food and beverage industry, along with best practices and technologies to address them. Food and beverage manufacturers have unique considerations when it comes to compressed air leaks because product consistency is critical to brand reputation and compliance, especially since production plants and equipment are subject to strict controls and regulations to avoid contamination.
In food and beverage plants, multiple air compressor assets connect through pipes to deliver compressed air in order to move product, operate pneumatic tools or pump liquids for a variety of purposes in production chains, packaging and cleaning. Here are some examples: • Snacks and nitrogen air cushioning: Nitrogen flushing is used to fill bags to air cushion delicate snacks to prevent damage. Oxygen is
excluded for use because it reacts with food products, especially those made with oils.
• Food and cleanliness: Compressed air is purified and filtered to ensure food safety and to maintain the proper pressure dewpoint needed to prevent microbial growth.
• Fruit and vegetable peeling: In preparation for packaging, pressurised air jets efficiently remove peels from fruits and vegetables. High-pressure compressed air is also used to cut foods as a cleaner alternative to knives or blades.
• Breweries, fermentation and bottling: Compressed air increases oxygen levels to complete the bacterial fermentation process. Air compressors reduce residual oxygen during bottling and bottles are flushed with carbon dioxide and filled with beer using pneumatically powered machinery. Breweries operate in warm environments, and therefore systems are more vulnerable to leaks.
Air leaks at any point can slow down production, affect product quality, create safety or contamination problems, or all four — and damage the bottom line.
24 May 2021 Components in Electronics
Hidden costs
Compressed air and gases need to be available at a specified pressure to achieve production targets, yet many facilities accept air leaks as a cost of doing business. Those costs can be high: a leak that can’t be seen or heard costs $500 per year per leak. Easily felt and heard leaks can cost much more as noted. Multiple factors associated with air leaks negatively impact profitability: • Lost efficiency: Compressed air systems not regularly maintained after installation could lose 20 to 30 per cent of compressed air in leaks alone.
• Additional expense: Pressure drop is often misdiagnosed as equipment failures, resulting in additional capital investment in new air compressors.
• Downtime: Lost production time from pressure drops or installing new equipment will require equipment downtime and negatively impact planning schedules. Unplanned downtime costs an average of $200 per minute making it critical to avoid.
• Product quality: Insufficient pressure results in defective package sealing or the
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