Efficient compressor system for packaging solution company

A manufacturing, design, and packaging solution company in the Southwest had a combination of old belt driven screw compressors operating at 10 bar(g) totalling around 500kW.

HPC and its authorised distributor completed an in-depth site audit and air demand survey, identifying the following:

  • Disorganised and leaking distribution piping, whereby a recommended redesign using modern distribution piping was proposed.
  • Compressed air generation pressure higher than required for point of use application. (Probably set like this to compensate for leaks, pressure drops, and lack of compressor control).

HPC Sigma Air ManagerUsing HPC’s Energy Simulation Software and the customer’s compressors operating data, HPC was able to simulate the existing annual air consumption of over 1,500,000kWh with an electricity cost of £369,000.00 per year.

Using this software, HPC then simulated various improved compressor options, whereby the best energy performing compressors were selected to meet the customers air demand profile.

HPC and its authorised distributor then supplied and installed a combination of both fixed and variable speed direct drive air cooled compressors with an HPC SAM intelligent computer compressor controller, operating at a reduced system pressure of 8 bar(g) to reduce wasted and unnecessary energy consumption.

The distribution pipework was also upgraded to reduce the waste of both energy pressure drops and air leaks.

Overall, the customer’s energy consumption dropped by 23 per cent or 336,000 kWh, saving £82,656.00 per annum. With the cost of energy continuing to increase there is now an even greater benefit to the customer.