Chicago-area injection molding firm Intec Group, LLC. is saving hundreds on their annual vitality invoice by upgrading to a VSD compressor and VSD dryer from PneuTech. Due to vitality incentives from ComEd, they saved hundreds extra on their buy. Their new compressor permits them to ramp up manufacturing when wanted whereas decreasing vitality consumption, upkeep prices, and compressor put on and tear.
Pete Bardgett, the Enterprise Growth Supervisor for Intec Group, says, “These price financial savings helps Intec proceed to be extra aggressive within the market when quoting new alternatives; this straight offsets the continued will increase of electrical energy. If our competitors isn’t doing these sorts of issues, then they should be elevating costs to take care of margins the place we will proceed to take care of margins whereas being a lower-cost different for our prospects.”
The Problem: Enhancing Power Effectivity and Reliability
Intec makes use of compressed air to run their injection molding equipment. Maintaining with buyer demand requires lots of air–and lots of vitality. The corporate maintained a number of fixed-speed compressors, together with a 100 HP PneuTech rotary screw compressor, two 30 HP Sullair rotary screw compressors, and a 75 HP Sullair rotary screw which was seldom used.
The fixed-speed compressors drew most vitality always whereas powered on, whatever the precise demand for air. An audit of the compressed air system recognized important inefficiencies.
The Fluid-Aire Answer: Upgrading to VSD with a ComEd Power Incentive
The Fluid-Aire staff performed a knowledge logging examine to find out the general effectivity of the system. Amperage knowledge loggers had been connected to the principle motor of every compressor. Changing amperage knowledge to CFM enabled an evaluation of whole demand vs. CFM provide for every hour of plant operation over seven days. This evaluation confirmed that changing among the fixed-speed capability with a variable-speed compressor would end in substantial vitality financial savings. “Working via the technical particulars and choices obtainable for our improve was made very straightforward primarily based on Fluid Aire coming in and making the real-time evaluation of precise demand,” Mr. Bardgett says. “This allowed us to make choices primarily based on precise outcomes moderately than engineering estimates.”
Based mostly on this evaluation, they determined to switch the 2 smaller Sullair rotary screws with a 125 HP PneuTech Water-Cooled VSD Rotary Screw Compressor. Additionally they upgraded their non-cycling refrigerated dryer to an energy-saving VSD refrigerated dryer. Mr. Bardgett explains, “VSD was chosen primarily based on continuous variability of demand in our plant and this was probably the most cost-effective option to tackle the continuously altering demand.”
Energy incentives from ComEd, their vitality supplier, allowed them to scale back their capital prices, too. Prescriptive rebates on energy-saving VSD gear gave them $10,625 again on the compressor and $3,750 again on the air dryer–a financial savings of almost 20% on the brand new gear price.
The Consequence: An Environment friendly System with Room for Future Progress
The brand new VSD gear permits them to ramp CFM up and down to fulfill demand in real-time. They had been additionally capable of scale back total plant strain barely. The mixed annual financial savings from upgrading to the VSD gear totaled greater than $18,000.
- Unloaded price: $ 14,827.75
- Inefficiency price: $ 1,210.84
- Strain discount financial savings: $ 978.26
- Annual price of sump blow-down: $ 1,102.51
- TOTAL ESTIMATED SAVINGS: $ 18,119.35
Upgrading to a more moderen, extra environment friendly compressor offers different advantages, too, together with much less put on and tear on the compressor, decrease upkeep and restore prices, and fewer warmth and noise within the plant. The brand new compressor additionally offers extra constant output for manufacturing machines. The older compressors and dryer had been retained to be used as a backup system. They now have loads of extra capability to make sure that they’re prepared for progress sooner or later. As Mr. Bardgett says, “The ComEd element of this allowed us to spend a bit extra up entrance in order that we might save extra on an annual foundation, so it was a key element to selecting the precise gear.”
Simply the Information
- 125 HP PneuTech Water-Cooled VSD Air Compressor, 148 – 635 CFM
- PneuTech Refrigerated VSD Air Dyer, 1250 CFM
ComEd Power Incentives Utilized:
- Compressor: $10,625
- Dryer: $3,750
Estimated Annual Power Financial savings: $18,120