Pneumatics & Hydraulics


Use compressed air efficiently

Technews Industry Guide: Sustainable Manufacturing 2021 Pneumatics & Hydraulics

Is your business sustainable into the coming years? To attain sustainability, one of the areas that needs great attention is compressed air efficiency within the plant. By focusing on this, plant owners can dramatically reduce their compressed air costs, leading to lower emissions, higher profits and a more sustainable operation.

With air compressors being one of the bigger consumers of energy in many plants, it pays to keep tight control of compressor station power costs. Focus points include:

• Compressor performance testing.

• Elimination of air leaks.

• Compressed air quality across the plant.

Performance testing

Accurate compressor performance testing is now readily available. Artic Driers has a portable package to benchmark an air compressor’s air flow performance vs. its power consumption. By measuring the pressure, flow rate and power simultaneously, an accurate measurement of m3/kW can be obtained. This can then be compared against CAGI (Compressed Air and Gas Institute) results, or the supplier’s data sheet.

This information can be used to determine if a compressor needs an overhaul. Performance levels before and after overhaul can also be measured to compare the air flow performance pre- and post-service. For anyone considering purchasing a preowned compressor, it can also serve as proof of a compressor’s ‘health’ status.

Air leak detection

Using the S531 leak detector, air leaks can be quickly identified. Finding and repairing air leaks is vital to prevent the waste of expensive compressed air. With compressed air costing around R0,13 per m3, losses due to leaks can cost a company hundreds of thousands of Rands per annum.


To illustrate, it is estimated that the average factory has a leak rate equal to 20% (or more) of the produced air volume. A 160 kW air compressor with a simple service plan, when running 24/7/365, can cost up to R1,5 million per annum to operate. A 20% leak loss will easily cost some R300 000 every year.

The use of ultrasonic leak detection and flow meters will quickly identify leaks. The S531 ultrasonic leak gun locates the leak, grades the severity, and provides an accurate cost of the air being wasted, all at the same time. It can even write the management report.

Compressed air quality

Poor compressed air quality inevitably affects production. The efficiency of robotics and pneumatics suffers, while automation systems are impaired and equipment lifecycles shortened. Appropriate compressed air quality is essential to avoid debilitating outages. Compressed air contamination will also increase wastage because drain traps and drain legs get left open to purge water and oil from the air distribution system. It is therefore essential to:

• Remove water oils and other contaminants from the airlines with a suitable air dryer.

• If a twin-tower chemical air dryer is used, fit it with a dewpoint controller to reduce purge air wastage.

• Do not run compressors at higher pressure than necessary – it wastes power.

• Design the ring main with a view to easy expansion, minimal corrosion and adequate condensate drainage.

• Reduce airline pressure drops.

• Fit inline filters sparingly, they can cause pressure drops. Rather concentrate on decontamination in the compressor room.

• Ensure air speeds are kept low to reduce pressure drops.

• Perform an air leak audit every three months.

• Benchmark production lines with flowmeters to ensure proper use of air.

Artic Driers can test compressed air quality to ISO 8573 standards, with portable or fixed base station equipment, and offer compressed air leak audits, dew point and flow tests.

The newly imported S600 portable Air Purity Analyser from SUTO-iTEC is perfect for clients that need to monitor and prove the quality of their compressed air supply and system to ISO 8573 standards.

Conclusion

Efficiency, minimising waste, reducing downtime and preventing unplanned outages are the keys to compressed air cost reduction and long-term company sustainability.


Credit(s)



Share this article:
Share via emailShare via LinkedInPrint this page

Further reading:

Servo motor series for explosive environments with expanded certification
Pneumatics & Hydraulics
Parker Hannifin’s ongoing commitment to safety and performance in hazardous environments is evident in the new certifications and product improvements for its EY and EX servo motor series.

Read more...
Precision matters: Unravelling the intricacies of hydraulic cylinder honing
Pneumatics & Hydraulics
This article dives into the intricacies of hydraulic cylinder honing, shedding light on its significance, process and the technology behind achieving unparalleled precision.

Read more...
The six pillars of hydraulic system health
Hydrasales Pneumatics & Hydraulics
Hydrasales, a leader in hydraulic and lube oil industry solutions, offers an extensive range of condition monitoring products designed to safeguard your systems. Here are six essential checks for hydraulic system health to keep your systems in optimal shape.

Read more...
Compressed air preparation
Artic Driers International Pneumatics & Hydraulics
The choice of compressed air dryers is driven by the air quality demands of your plant.

Read more...
Compressed air treatment do’s and don’ts
Artic Driers International Pneumatics & Hydraulics
As a long-established importer and manufacturer of air dryers, Artic Dryers often sees the results of poor installation and issues with aftercoolers that create serious problems in air drying systems.

Read more...
Next-gen air compressors for plastics manufacturer
Pneumatics & Hydraulics
Integrated Air Solutions has reinforced its partnership with global compressor manufacturer, ABC Compressors by facilitating the installation and commissioning of two next-generation direct-drive ABC machines for a prominent plastic manufacturer in South Africa.

Read more...
Electrohydraulic shredding of galvanic waste
Pneumatics & Hydraulics
Galvanised parts are among the last big challenges for recycling. ImpulsTec is implementing shockwave or electrohydraulic shredding technology, for the separation of complex material compounds in industrial processes.

Read more...
A leap forward in electrohydrostatic pump technology
Customized Motion Controls Pneumatics & Hydraulics
Moog has launched the EPU-G, the latest addition to its Electrohydrostatic Pump Unit portfolio.

Read more...
Revealing the value of filtration
Hydrasales Pneumatics & Hydraulics
The life and reliability of hydraulic systems are greatly affected by the presence of particulate contamination in the lubricant. However, in the face of potential contamination there is hope. The cleaner the fluid, the more reliable the system or process, and the longer the lifespan of its components.

Read more...
Bushings for movie prop platforms
Pneumatics & Hydraulics
A provider of engineering services in the hydraulics and pneumatics industry anticipates new orders in 2025 for movie prop platforms that use Vesconite bushings with a low coefficient of friction.

Read more...