One of Egypt’s leading emulsion polymers’ producers was seeking a robust and reliable air compressing solution for constant air supply with variable pressure compression. That’s when they adopted ELGi’s eco-friendly, energy-efficient EG Series Screw air compressors to increase reliability and ease of use at its manufacturing operations. 

According to reports, the polymer emulsion’s market size is expected to rise from USD 25.2 bn in 2020 to USD 38.1 bn by 2025.1 Despite the shock from COVID-19, considered unparalleled since the great depression and the IMF warning of an uneven slump ahead, the growth prediction of 8.6% CAGR is heartening for all stakeholders. 

The prediction is based on solid fundamentals and is not just a result of biased speculation. Market growth is driven by regulatory mandates, emerging energy disruptions, shifting consumer dynamics, and growing end-user industries, principally from emerging countries. 

Strict regulations are fuelling product demand. Stringent pro-environment guidelines around toxic chemical emissions and directives regarding the usage of water-based emulsion polymers over synthetic products. Various end-user industries like paper, textile, and consumer durables are adopting polymer emulsion to control noxious emissions. Additionally, the auto industry, coupled with the construction industry, is driving the global polymer emulsion market. Owing to a growing demand for green buildings, the global construction market is poised to grow by 85% to $15.5 trillion worldwide by 2030.² 

The Polymerisation Process 

Often called ‘products by process,’ emulsion polymers signify that the composition of the bulk polymer is as important as the process of making it.  

Alcohol is an emulsifying and dispersing agent for paper coating, board coating, water-soluble film, textile sizing agent, paper and wood adhesive, release liners and carpet coating among others.     

The emulsion polymer manufacturing process is very complicated. 

With traditional energy-guzzling installations, mounting pressure loss increased startling load, and rigidity in temperature compromising air quality, the need was for advanced air compressors with high-end design and advanced features. The company was seeking a partner to help deploy compressed air systems that can withstand the harshest of environmental conditions while saving energy, costs, and reducing Co2 emissions. 

From 2018, the company started leveraging ELGi’s total compressed air solutions to achieve best-in-class energy efficiency.  

ELGi’s eco-friendly, energy-efficient EG Series Screw Compressors delivered constant air supply with variable pressure compression. Through its in-house, proprietary η-V profile rotors designed to run at optimum speeds, it reduced pressure losses and increased efficiency. ELGi’s 1000 litre high-pressure air receiver, designed to ASME standards and built-in ELGi’s dedicated facility, acted as an enabler between the compressor and the variable pressure caused by demand waves helping reduce the loading and unloading cycle pressure on the compressor. 

Airtime refrigeration, air dryers, and filters prevented real-life problems like unwanted abrasive sludge, corrosion of piping, and erosion of pneumatic tools.  

ELGi’s Airtime refrigerated air dryer has ensured longer life of compressed air system through the efficient removal of the condensate and contaminants. As per international protocol, ELGi uses ozone-friendly R 134A gas as the refrigerant which has zero ozone-depletion potential. 

The organisation specifically selected the ELGi EG Series compressor on account of its following features and benefits: 

• Reduced startling load: The new generation intake valve system is designed for low losses. 
• Moisture-free air: The EG Series air compressor, with its custom-designed centrifugal type moisture separator and automatic drain, removed over 99% of bulk water from the compressed air. 
• Cool air: Efficient air cooling from an integrated fan-motor maintains a low temperature, resulting in the increased lifespan of the motor.  
• Robustness and reliability: Designed to perform in extreme temperatures, the compressors have performed well in cold, hot, and humid, as well as arid conditions.     

CONCLUSION 

The partnership with ELGi has enabled the organisation to address various operational requirements, including the need for clean, moisture-free, oil-less (1ppm) air that is free of other contaminants as well. The emulsion polymer maker has also been able to reduce the life cycle costs for its air compressors, besides realising significant energy savings and uptime warranty. 

To know more about our offerings in the manufacturing sector, do reach out to us at communications@elgi.com or call us 1800-203-3544 (Toll-free, India). 

1. Polymer Emulsion Market worth $38.1 billion by 2025 – Exclusive Report byMarketsandMarkets™

https://www.prnewswire.com/news-releases/polymer-emulsion-market-worth-38-1-billion-by-2025–exclusive-report-by-marketsandmarkets-301124978.html 

2. Global Construction Market to Grow $8 Trillion by 2030: Driven by China,USand India 

https://www.prnewswire.com/news-releases/global-construction-market-to-grow-8-trillion-by-2030-driven-by-china-us-and-india-544142522.html 

However, not many are aware that compressed air is a major power source in the healthcare sector and saves many lives. It is a key component that enables the functioning of modern medical equipment. Be it artificial respirators or surgical instruments, air compressors power a number of systems in hospitals and dental clinics.

Let us look into some of these in more detail:

Operation theatre

Medical-grade compressed air, free from contaminants such as oil, dust particulates, bioburden and water vapour, is administered to patients for anaesthesia and inhaled medications during surgeries. It keeps them with breathing and makes them feel comfortable during invasive procedures. Air compressors also help run several handheld medical tools and pneumatic devices in the OT.

Treatment of severe respiratory conditions in the ICU

Life support systems in Intensive Care Units (ICUs) are powered by air compressors. Medical grade air compressors deliver clean and dry air while running ventilators. They also power the incubators that provide a safe space to new-born babies as their vital organs develop. The controlled flow of air helps reduce unsafe levels of oxygen exposure and enables easy breathing for patients.

Dentistry

Air compressors are also at the core of dental treatments and surgeries. They help operate drills, scalers and other handhelds used by dentists in tooth extraction, root canal process, teeth cleaning and other invasive procedures.

Besides providing the cleanest of air for equipment, dental air compressors must also function without making much noise – this is necessary to enable dentists to focus on their work and the patients to stay relaxed. Small air compressors with filter silencers can significantly reduce the noise a unit makes.

Hospital maintenance

Compressed air is the best resource to clean dusty surfaces in any facility, making it useful for hospitals that must be kept very clean. Air compressors also power a number of other tools used in the repair and maintenance of medical equipment such as nail-guns, impact hammers and others.

Hospital maintenance teams also use air compressors to inflate mattresses and the tyres of wheelchairs, stretchers and service carts.

Air compressors that supply medical-grade air

Medical air compressors are specially designed to distribute air that does not have any traces of fine particles, oil, odour or moisture. Such air is used only for patient care and calibration of devices for respiratory applications.

Oil-free air compressors are the best models to supply medical-grade air Since they use materials like Teflon for lubrication, there is no trace of harmful oil in the air output of these compressed air systems.

It is also critical to eliminate water from healthcare compressed air systems because moisture is corrosive and can cause significant harm to the units. Besides damaging distribution pipelines and air receivers, it may lead to mould growth on equipment used in medical treatments. Water can also freeze in control lines during cold weather, resulting in faulty operation of associated applications.

Regardless of airborne moisture or vapour from system condensation, water in any form is harmful to systems run by medical air compressors and can lead to multiple breakdowns and repair bills.

More alarmingly, any bacterial contaminant or pathogens mixed with moisture, put patients’ lives in danger, defeating the very purpose of using compressed air in medical facilities.

Smooth functioning of air compressors

The key component requiring maintenance to avoid water in medical air compressors is the air dryer. While buying accessories, ensure that you choose the right size of dryers and fit them carefully, considering the amount of moisture that they can hold.

Service or replace the dryers when required because, in time, they tend to lose their ability to stop vapour from passing through the air compressor.

As part of your routine air compressor maintenance, check the condensate drains to prevent them from carrying moisture downstream into the linked medical systems. Get the clogged drains cleaned thoroughly and if there are any other signs of damage, contact a professional to make necessary repairs or replacements.

ELGi offers air compressors and accessories for the healthcare industry for select applications and to support your facility maintenance tasks. To know more about these models or to sign up for an annual maintenance package, contact our team at 1800-425-3544 (India tollfree) or write to us at communications@elgi.com .

There are several parameters to keep in mind while buying an air compressor. Apart from deciding the size, rating expressed in CFM (for airflow), and bar (for air pressure), you also have to choose between an oil-free and oil-lubricated system.

The choice depends on the kind of applications where you intend to operate your air compressor. This is why, it is good to understand how these compressed air systems work and the applications that they’re used for.

Air compressors convert normal air into its high-pressure, denser form for uses in a wide range of environments.

From small, portable models for safe supply on-the-go, to huge commercial installations that fuel complex industrial processes, they vary considerably in size and configuration to best suit all kinds of needs.

ELGi offers compressed air solutions to multiple industries, and here’s a list to name a few:

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.

Portable compressors are used as an energy source in mining because of its flexibility and maneuverability to use at sites with diesel engines.

Applications such as drilling holes in blue metal quarry with jack hammer and crawler drilling using compressed air is more common at sites.

ELGi’s PG 300-100 & PG 400-100 dominate in performance for jack hammer application in blue metal quarry. Its innovative airend screw profile offers high standards of energy efficiency and reliability, with long durability. With heavy duty Ashok Leyland diesel engine and turbocharger options for long-term operation, this concept encodes to increase the efficiency of the compressor system significantly, especially for long productivity in regular operation.

Our customers have found that both our PG 300-100 and PG 400-100 perform better than other compressors, with 6% less fuel consumption per hour than other brands.

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.

You would find literally everything you need or did not know you needed at a supermarket. Choices of brands, products, sizes, weights, you name it! And while you find yourself spoilt for choice, there is one thing common with all these offerings and that is the packaging. Each of these products is ready and safe for use because of compressed air.

Compressed Air in Packaging Industry

As online shopping continues to rise, the packaging sector sees an expansion in its industry. Compressed air assumes a pivotal role in the manufacturing and packaging operations across various global sectors. Its applications span from cleansing, aligning, shaping, to sealing a wide array of packaging items.

Compressed Air in Food Industry

Last year, the global food packaging market crossed over US$ 302 billion in market value. Compressed air plays a vital role in safely transporting food items and other products around the factory or to their desired location, without any contamination or deterioration in quality. Compressed air is used to shape and seal cartons and boxes, manufacturing products like PET bottles and thoroughly clean all containers before they can be filled with liquids.

Oil-free compressors are indispensable in the food and beverage industry, ensuring product safety and quality by delivering contaminant-free compressed air. They are utilized for tasks like pneumatic conveying, bottling, and packaging, where maintaining a pristine and hygienic production environment is paramount.

Use of Compressed Air in Pharmaceutical Industry

In the pharma industry, oil-free compresses are used to manufacture products including pills and tablets. These tablets or pills are then safely placed in bottles, after the moisture has been removed, and then sealed airtight- maintaining the highest level of clean and sterile compressed air.

Please know more about the significance of oil free air in pharmaceutical industry.

But what makes an automobile the thing of dreams?

High-quality equipment for a high-quality vehicle

Automobiles have been engineered into the modern-day way of life, which is what has driven many manufacturing feats and innovations and changed the face of the entire industry for the better. Manufacturers today can supply consumers with safer, more fuel-efficient and reliable vehicles owing to the improved manufacturing practices through the use of compressed air systems.