Executive summary 

ELGi Compressors Europe, supported the Italian Red Cross with its urgent compressed air requirement. In line with ELGi’s corporate philanthropic approach, ELGi Europe swiftly and comprehensively made a charitable contribution of an air compressor package for one of Italy’s Red Cross logistic hubs serving the Turin area.

Background 

In February 2021, Italy commemorated the first anniversary of the country’s first COVID-19 case. Vo, a township in the province of Padua in the Veneto region, had registered the country’s first COVID-19 death on February 21, 2020.

During the first wave in 2020, the surge in infections was fast and relentless, as the virus spread from northern Italy to the rest of the nation. Strict lockdowns followed soon after, and several restrictions remained in place to curb the spread of the virus. By the end of the year, the country had registered over two million cases, and the virus continued to have a massive impact on health and society. 

The country-wide lockdown led to a situation the modern world had never seen before. Humanitarian aid in the form of food, medicine, clothing and other essential supplies became a priority as millions required help to secure basic necessities. 

About IFRC 

The International Federation of Red Cross and Red Crescent Societies (IFRC) is the largest humanitarian network globally, helping people in times of crisis. With more than 13.7 million volunteers across the globe, the organization supports over 150 million people facing disasters and health emergencies. 

The Red Cross’s strengths are its vast volunteer network and ties with the community and corporations that assist vulnerable people. Its community-based expertise helps improve the living standards of people in distress, while partnering with stakeholders who can sustain development efforts. The Red Cross volunteers work with multiple stakeholders to shape disaster responses and build resilient communities.

The Italian Red Cross, established in 1864, has been coordinating its COVID-19 response with national and international parties. From March 2020, it has been working with Italy’s Ministry of Health and looked for donations to handle medical supplies and other equipment.

The Red Cross Italy’s Polo Logistico Valle di Susa facility, located in Bussoleno, has been supplying the metropolitan region of Turino with medicines, meals, and supplies during the ordeal. In addition to traditional rescue and ambulance activities, the Red Cross Italy catered to the needs of people in isolation, sanitation of public spaces, evacuation of patients, while assisting withscreening. . 

Furthermore, the facility was fulfilling the accommodation needs of healthcare staff, handling support requests, and running a call centre to investigate seroprevalence.

The challenge 

The COVID-19 pandemic pushed the Italian Red Cross’ efforts to the limit. While the network has experience dealing with first-aid and emergency response, the speed with which the pandemic spread, was unprecedented and caused a stretch on resources and equipment. 

To meet the rising demand for humanitarian aid and bolster the work of its volunteers, the Red Cross Italy requested for various equipment, parts and supplies to keep operations running. With hundreds of thousands of items such as medicines, groceries, clothing, and more, passing through the logistics centre, industrial-grade equipment was needed to maintain vehicles and tools. 

The Italian Red Cross’ existing piston compressor could not meet the demand for high-quality compressed air, and the situation demanded an immediate upgrade. This prompted the Italian Red Cross team to contact ELGi Europe, who immediately responded with an air compressor that addressed and enhanced the operational capacity of the Italian Red Cross logistics centre.

The solution 

ELGi Europe delivered and installed an EN series air station comprising a receiver and fridge dryer, in just a matter of days. The plug and play solution enabled high reliability, ease of maintenance and a small footprint. These features came in handy at the Red Cross’ logistics centre in Italy, as volunteers needed all the time and space they could get for sorting supplies. 

“The COVID emergency has placed pressure on all people and equipment. We contacted ELGi and other companies asking if they could support us with a new air compressor to enhance our operational capacity at the logistics centre. ELGi responded immediately, visited our Centre, analysed our compressed air needs and within days, provided not just an air compressor, but a complete system including a tank and dryer,” said Michele Belmondo, Site Manager at the Red Cross Bussoleno.

The ELGi EN Series is a complete solution for obtaining high-quality compressed air and requires very little maintenance as there is zero leakage due to integrated components and connections. The compressor contains ELGi’s unique assembly design, ensuring energy efficiency and minimal pressure drops. The compressor also has the lowest noise level in the industry, making it the perfect addition to the Italian Red Cross facility. Finally, with cleaner suction air keeping internal components clean and low oil-fill needs, the EN series compressors’ long-lasting life enabled the Italian Red Cross volunteers to focus on what they do best i.e., uninterrupted, critical humanitarian work.

Benefits

 With the high-quality ELGi EN series Air Station, the Red Cross Italy was able to achieve the following:

• Meet the gruelling humanitarian and supply needs of the metropolitan city of Turin 
• Be available 24/7 with transport and equipment that can be mobilised quickly 
• Assist local city authorities with sanitation and monitoring activities, preventing the spread of the virus 

Conclusion 

“At ELGi Compressors Europe, we aspire to be ‘Always Better’ in everything we do – and this includes building long-lasting partnerships with our employees, customers, channel partners and the local communities where we operate. We are grateful for the opportunity to support the Italian Red Cross in its tireless efforts with caring for the local community during these challenging times,” said Chris Ringsletter, President at ELGi Europe.

ELGi catering to the Red Cross needs in Italy, when it mattered most represents its fundamental values. The COVID-19 virus has known no borders and while we strive to emerge from the pandemic, we’ve seen individuals, companies, and governments come together and offer their expertise to help each other. ELGi is championing this by doing what it does best – supplying high-quality air compressors to meet emergency demands and enabling the Red Cross Italy to fulfil its humanitarian commitments.

Like any other machine, air compressors need regular maintenance and periodic replacement of parts that get strained with continuous use. By changing the worn-out components in time, you can ensure optimal functioning and better durability of your unit while also saving time and money on unnecessary repairs. 

While these spare parts are often available in the market, and in many instances even come at attractive price-points, it is critical to procure your air compressor’s components only from Original Equipment Manufacturers (OEMs).  

Benefits you enjoy when you purchase only genuine parts:  

• Warranty – for repair, replacement or refund if the part fails to function optimally  
• High product quality  
• Longer lifespan  
• Higher productivity  
• More energy savings  
• High reliability  
• Ease of service and maintenance  

Let’s take a look at the parts that need to be replaced or replenished for the commonly used rotary screw air compressors:  

Dust filters and oil separators  

The air & oil filters and the oil separators are critical parts of air compressors as they prevent damage and performance loss caused by dirt in the internal system.  

Dust particles from inlet air can damage your air compressor’s rotors. This can reduce the quantity of compressed air delivered to associated tools, with continuous energy consumption.  

Dust also lowers the lifespan of the air compressor element and the oil separator. When it gets mixed with the oil that lubricates the rotary screw air compressor, the oil becomes impure and less effective.  

Additionally, dust harms the bearings and the bearing housing, negatively impacting the air compressor element and may even lead to element seizure. 

Therefore, it is essential to use only genuine air compressor filters and oil separators when it is time to replace the originally-fitted units. Such filters have strong dirt reduction capabilities. They are devised to endure high operating pressures and fluctuating temperatures while maintaining efficient performance with low power consumption.  

Airline filter cartridge   

If you replace your air compressor’s line filter cartridge with a counterfeit piece, it will reduce the filter’s efficiency and allow dirt particles to enter the air network. This will result in pressure drops and high energy consumption by the compressed air system.  

Using a non-genuine filter cartridge will also result in more frequent replacements or repairs, leading to a higher total lifecycle cost of the air compressor. Hence, always insist on buying genuine airline filters.  

Lubricating oil 

A key consumable in oil-based air compressors, is that the lubricating oil absorbs heat while also safeguarding the unit from dust accumulation and rusting.  

While some users have a notion that ‘any oil’ can be used for lubrication, the fact is that a poor quality oil reduces the durability of an air compressor. If oil greases the system components ineffectively, it can cause the formation of sediment in oil circuits and over the moving parts. Such developments increase the risk of oil oxidation and corrosion of metal parts in the compressed air system. 

Using genuine oil or lubricating fluid offered by your air compressor supplier can ensure effective lubrication, prevent equipment breakdown and derive better performance from your rotary screw air compressor.  

Authentic air compressor oil combines the finest quality of case oil with required amounts of additives that make the product suitable for lubricating an industrial compressed air system.  It is viscous at low temperatures and has high oxidation resistance. 

With a genuine lubricating oil, you will need to top-up less frequently, have lower disposal cost, require less maintenance and face lesser downtime incidents.  

Important points for you to take note: 

Besides procuring spare parts and consumable fluids from OEMs and recognised suppliers, it is also critical to have a proper service kit comprising the hand tools for safe replacement of parts, and for best results, you should get your compressed air system serviced only by experienced repair personnel.  

ELGi offers a range of industrial-grade air compressors for reliable functioning. We also provide bona fide spares that maximise the uptime of your air compressor system and reduce operating costs. With our Annual Maintenance Contract (AMC), you get the assurance of always getting compatible and long-lasting parts along with on-time service by professionals. To know more about our solutions, visit https://www.elgi.com/in/services-parts/ 

Inspite of the availability of spare parts in the market at attractive prices, it is critical to procure your air compressor’s components only from original equipment manufacturers (OEMs).

Purchasing spares from authorised dealers will give you benefits like:

• Warranty
• High product quality
• Longer lifespan
• Higher productivity
• More energy savings
• High reliability
• Ease of service and maintenance

The parts that need to be replaced or replenished include:

Consider repairing your equipment at various stages of its lifecycle, where an expert will tend to the parts and pieces which need restoration. However, sometimes temporary bandages do not suffice, and you are faced with the decision of replacement.

When should you consider repairing your equipment and when should you replace it?

If compressed air is essential to your day to day business operations, the decision regarding repair or replacement becomes an important one. Unnecessary repairs can result in lower capacity of output. And not replacing your equipment in time can result in breakdown.

While it may be reasonable to opt for repairs, buying a new compressor could be a more practical choice in the long term.

Cost consideration

The cost of electricity comprises approx 75% of the cost of an air compressor through its life, while a new air compressor may only come up to a fraction of this figure (when compared to the cost of ownership over a ten-year period).

Although cost may be your primary concern, it is worth noting that the RoI depends on maintaining maximum uptime over time.

Signs to look out for in your air compressor

Comprehensive checks are necessary to identify the signs of reduced performance. Identifying certain areas of repairs or timely interventions can help you save on energy consumption and cost.

• Oil levels: Check the levels of lubricants regularly and make adjustments as per your operational needs.
• Spare parts: If the parts are emitting loud noises or consuming excessive lubricant, check if they are   Excessive corrosion may also affect parts that are left unattended.
• Cooling systems: Excessive heat discharge, indicates that there is a problem with your cooling system.
• Fuse: If your air compressor regularly blows the fuse, chances are that the size does not support the electrical load of your compressor. Do replace these with a fuse that can bear the load.
• Belts: Belts that are either too tight or too loose, can wear out Timely adjustments can help you save on repairs.

If your compressor shows signs of wear, rusted piping, excessive vibrations, overheating or metal deposits in your oil analysis, it’s time for a thoroughly inspection. You can consult an ELGi air expert to check if it’s time to purchase a new compressor altogether or explore possibilities of repair to deliver required air flow at good efficiency.

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 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 is mandatory to maintain the quality of air, it is also an energy saving opportunity. Delaying an air filter change costs you more than you think! Clogged filters can lead to pressure drops and 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 air by removing oil and water but also particulate matter to a certain extent. Installing pre-filters for suction air and cooling air 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. 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 air line 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.

6. CONSIDER A VFD
   Screw compressors should run under full load.
   If the usage pattern varies, consider a Variable Frequency Drive (VFD) for upto 35% reduction in energy cost. A VFD helps regulate the energy consumption based on demand fluctuations, ensuring energy efficiency. ELGi’s VFD has helped clients realize up to 215% savings in maintenance and energy cost with payback as low as 7 months.

7. PERFORM QUARTERLY MAINTENANCE CHECKS
   The importance of maintenance cannot be overemphasized.
   Regular maintenance can help you identify and accurately measure leaks in the circuit. They also reduce the chances of breakdowns leading to maximum uptime and productivity.

8. PREVENT MISUSE OF AIR
   Wasted air is wasted money. Invest time and money in training employees for efficient compressed air management. Create maintenance logs and update them on a regular basis, recording abnormalities or leaks in the systems. Systematically label leaks with proper tagging and prioritize repairs and plugging of leaks.

9. RECOVER HEAT
   It’s common knowledge that heat is produced during the process of air compression. If not used judiciously, all the heat energy goes to waste. Over 90% of the heat produced can be recovered and utilized for heating air or water at the facility.

10. GET AN AIR AUDIT
    Air audits enable companies to work with experts in the field and get valuable insights into their plant’s compressed air utilization. ELGi’s air audits chart out a customized and comprehensive energy management plan for your needs. Over the years, we have helped save millions of dollars in energy costs. Request an air audit now: http://www.elgi.com/contact-us/

In talks with Managing Director, Dr. Jairam Varadaraj, The Textile Magazine unearths the determinants of ELGi’s powerful claim in the compressed air business –– “we provide the lowest lifecycle cost in the world.”

In Part One, we followed ELGi’s evolutionary journey in manufacturing and design which makes a compelling case for sales of their air compressors. But ELGi’s approach to after-sales service is what makes them valuable partners for customers in the long-term.

Commenting on ELGi’s relationship with the Indian textile sector, Dr. Jairam Varadaraj said: “As a group we know textiles better than our competitors. This is because we have our own spinning mill in the group. We have been in the business of textiles for 40-odd years now. We know the pain points and challenges. Plus, we are based out of Coimbatore, a premier textile hub. Wherever you go across the country, people in the textile industry know ELGi.”

The company has a strong sales and service network spanning the length and breadth of the country. ELGi has an extensive team of more than 500 sales and service personnel with a maximum response time of eight hours. Elaborating on this, Dr. Varadaraj pointed out: “For us it is not just about responding when a customer calls. It is about restoring air. Today 96-97% of our customers get their air back in less than six hours. That’s a record nobody can beat. In fact, even our competitors acknowledge this strength of ours. We deliver uptime.

Generally we are there in about an hour. That’s the physical infrastructure. We also have a strong system in place where every defect, however small it may be, is registered at the factory by evening. We are also coming out with a SIM card based device which is incorporated in our compressors. It is in the testing phase. While others have also been offering similar services, we are doing it with a difference. The device talks to the compressor and gives a comprehensive performance report through an algorithm. The software then starts predicting. See, any mechanical device will degrade with wear. Failure takes place when you don’t notice this wear. With this monitoring, you will be able to get there before the failure. Predictive maintenance is what we offer. We have supplied about 55 machines with the device. By the end of this year, we will make it standard on all our machines. Many of our competitors offer it usually for large machines and invariably tied up with a service contract. We don’t want to follow that path. We firmly believe that the device is meant for us. More than our customers, we want to know how our machines are performing, for it will help us keep improving and stay ahead of the curve.”