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News Release from: Energair Solutions | Subject: EnergAir control system
Edited by the Manufacturingtalk Editorial
Team on 12 May 2006
Bottling plant cuts compressed air costs
by 30%
Bottling plant cuts compressed air costs by 30% and achieves a net annual carbon saving of 772 tonnes, following a recently completed energy efficiency improvement programme.
A recently completed energy efficiency improvement programme at the Britvic Beckton bottling plant has resulted in substantial energy savings and a positive impact on the company's carbon emissions allocation The programme employed auditors, Air Compression Technology to review and make recommendations on improvements to the high-pressure air generation system on site
This article was originally published on Manufacturingtalk on 17 Jul 2001 at 8.00am (UK)
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The recommendations resulted in a new EnergAir control system for each existing piston compressor, the integration of a new compressor and the installation of an overall management, control and PC visualisation package from EnergAir that provides integrated live control and reporting functions for the entire system, including the cooling, air preparation and building ventilation systems.
Kevin Cunningham, on the Britvic site management team commented, "Minimising the environmental impact of our operations is important to Britvic and reducing Energy Consumption is a key aspect of that policy.
We were aware that a large part of our energy expenditure is in compressed air and commissioned energy auditors Air Compression Technology (ACT) to benchmark and audit the high-pressure compressed air system during October 2004.
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ACT collated all the operational data, analysed it and then met with us to discuss the plant operational requirements in detail.
From this meeting we were able to establish accurate estimates for the possible savings and create a clear strategy for delivering and maintaining tangible energy, cost and carbon savings." Graham Coats, director of EnergAir Solutions, added: "PET bottling plants tend to work on far higher pressures than normal automated production lines, typically 40bar as opposed to about 7bar, requiring more power and often providing a greater opportunity for energy saving.
With the recent rises in energy costs and the experience we had gained form systems we have completed on other PET plants, we were confident significant savings could be realised." Kevin Course, ACT director, said: "Importantly from the client's point of view the results are also highly measurable; we now remotely collate data on a weekly basis from the on-site EnergAir communications module.
The data is analysed and reported back to the client on a quarterly basis.
The reporting and ongoing support from ACT ensures that Britvic is able to continually maintain optimum efficiency levels (measured in input kW against output m3/min) regardless of any future change in their compressed air demands." The table below summarises the improvement in system performance since the introduction of the compressor management/control system.
The system has achieved the energy gains by optimising the installed compressor set, stabilising the system pressure and allowing a careful but precise reduction in the system operating pressure.
Further energy gains are expected in the short term through effective management and further fine-tuning of the system.
* KPIs/results.
1 - Generation efficiency - improved on average by 5.46%.
2 - Cost per delivered m3 - decreased on average by 5.26%.
3 - Annual generation costs - decreased by 29.36%.
4 - Annual kWh used - net saving of 1,797,131kWh.
5 - Net annual carbon saving - saving of 772 tonnes.
* Note - all summary calculations are based on the cost per unit of electrical energy at GBP 0.032/kWh and is based on the system being operational for 8,400h/annum. Request a free brochure from Energair Solutions ...
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