Their distinct features can be understood in terms of:

Today, let’s read about a global leading elevator manufacturer, which chose ELGi’s EG Series screw air compressors for their newest plant in Pune to achieve their ambitious production targets for market expansion in India.

Today, let us read more about a leading fuel management system provider, which enlisted the help of ELGi’s EG series compressor for their facility in Sharjah, UAE.

One of our partners in the paper manufacturing industry was looking for ways to reduce their energy consumption. They identified that their air compressor was a major contributor to their energy bill.

SITE ANALYSIS:

They had many decade-old compressors placed in various locations of their plant. The older compressors consumed higher energy. The machines were also becoming difficult to maintain due to short consumable replacement cycles and an increase in maintenance costs. And any new compressor would have to be rugged in to run in harsh temperatures with minimal maintenance checks.

SOLUTION:

After a comprehensive study, we recommended that two of their existing 75kW machines be replaced with newer, larger 160kW compressors as a preliminary change to accommodate their budget and to increase efficiency.

RESULT:

It has been 1 month since we replaced the machines, and the paper manufacturer has recovered over 55% of their investment only through power. The newer compressors which offer more features also operate with less noise and are built to handle harsh temperatures and conditions of the site.

Every equipment in use needs an upgrade. Not only does an upgrade bring changes to the equipment in terms of performance but also features.

When it comes to the environment, both the consumer and the manufacturer understand the impact of a product on the environment. Hence, there is significant effort taken to reduce the environmental impact of products.

Over the past decade, a lot has changed in compressors. The air-ends which are the heart of the compressors have been improved to provide higher compressed air flow and consume lower power. The primary mover of the air-ends, the electric motor’s minimum efficiency has been incrementally upgraded as well. The unload power and power consumed by the cooling fan has also been reduced significantly by controlling the flow of oil into the air-ends and the cooler. The controllers have become smarter and can identify running patters. They can also control multiple other compressors as well.

After analysis, ELGi recommended replacing 2 machines with a larger one as a preliminary effort.

Two 75kW units were replaced with one 160kW improved state of the art oil lubricated screw compressor. Not only did it help increase the compressed air output but also helped save electricity. this effort helped reduce CO2 emission (in tonnes). The details of the savings are as below:

Typically, energy costs contribute to more than 75% of the total life cycle costs of a compressor. Appropriate selection of compressors will result in optimal energy utilization, thereby reducing energy costs significantly for the user.

It is a proven fact that about 70% of an air compressor’s lifetime cost comes from power consumption, which then increases your overall power consumption However, due to the effectiveness and capacity of production support extended by compressed air systems, that it is now an indispensable part of the factory setup, especially in the case of sensitive industries including healthcare, pharma, food & beverage, etc.

Many opportunities exist to reduce the energy used by compressed air systems, beginning with air assessment and air audit. Here are 10 expert tips to help you keep a tab on your electricity bill.

1. LOWER THE PRESSURE: We all know that working under pressure can be hard. Every additional bar of pressure can increase your power consumption by 7%. Set your air compressor at the lowest possible pressure for a specific application. Remember that increasing pressure does not compensate for a pressure drop in the system caused due to leaks, faulty piping, or choked filters. Install a pressure regulator for better control. It’s also important to calibrate your pressure gauges at quarterly intervals.
2. CHANGE FILTERS ON TIME: While replacing air filters, it is mandatory to maintain the quality of air, it is also an energy-saving opportunity. Delaying an air filter change may cost you a lot. Clogged filters can lead to pressure drops and also hamper efficiency. Ensure on-time service for a healthy compressed air system.
3. INVEST IN PRE-FILTERS: Not only do pre-filters (also known as coalescing filters) help purify the air by removing oil and water, but they also help remove the particulate matter to a certain extent. Installing pre-filters for suctioning the air, and for its cooling, can extend the life of your compressor and its consumables.
4. CLEAN UP: Besides keeping your air clean, ensure that you give your compressed air system a thorough dusting every few months. The presence of sludge, dust, or grime can have a big impact on the efficiency of the compressed air system. Pay special attention to compressor coolers and heat exchangers. Consider investing in a dedicated low-pressure air compressor, and airline for cleaning, to save power.
5. PICK THE RIGHT DRYER: Selection of the right sized air dryer for your compressed air system is crucial. Make sure the energy consumption of the dryer is in proportion to the demand. An oversized dryer can add to your electricity bill significantly.

While businesses focus on optimising production and reducing unnecessary costs, air compressor breakdown due to incorrect start-stop might lead to huge operational losses. Here is the need to work on a business continuity plan capable of handling the fast-moving variables of an outbreak like COVID-19.

As some countries across the world are going into lockdown while others are resuming business activities, it is important to follow few steps to ensure proper shut down and start-up of your air compressor and related accessories.

Re-evaluate your energy cost during operation and invest in energy saving products like ELGi Heat Recovery System.Know More