BISCUIT MANUFACTURE
Energy wastage due to lack of coordinated control. The system has five compressors, in two separate plant areas. The units were set to operate on their own internal pressure switches. The system was audited and found to have a wide pressure bandwidth and high levels of off-load (inefficient) operation. A control system was installed with a retrofit inverter to one of the compressor. No new compressors were required, minimising capital cost. In addition, non-loss autodrains and desiccant dryer dewpoint dependant switching was installed. A reduction of 32% in energy consumption was achieved.

FOOD MANUFACTURE
Energy wastage due to multiple isolated systems. The system comprised 3 isolated systems, each with high levels of off-load (insufficient) operation. An Ingersoll Rand N110K-2S inverter driven compressor was installed and the systems interlinked. An Ingersoll Rand TZV series non-purge desiccant dryer and high efficiency filtration was also installed. A reduction of over 35% was achieved

DAIRY
Energy wastage due to over-pressurisation of the system. The system was supplied by an efficient Ingersoll Rand N110K-CC compressor but pressure was always set to operational requirements. A control system was installed to reduce the pressure during non-operational periods. A saving of over 15% was achieved

DAIRY
Energy wastage due to incorrect plant specification. This system had a number of issues:

• An high efficiency inverter compressor that was undersized, resulting in operation within a ‘deadband’.
• Incorrect specification of the air treatment plant.
• Over-pressurisation of the system.

The solutions were:

• A retrofit inverter was fitted to the largest fixed speed compressor.
• Desiccant dryers replaced with high efficiency refrigerated units.
• A control system to coordinate plant operation and control pressure, reducing pressure in non-operational period

PRINTING
Energy wastage due to incorrect system specification. The system has a compressor as specified by the Press Manufacturer, Mailroom Manufacturer and Ink Pump provider. The system was audited and found to have significant over capacity. An Ingersoll Rand N30K inverter driven compressor was installed. Over 75% energy reduction was achieved

PRINTING
Energy wastage due to over-sized plant. The system was supplied by an Ingersoll Rand ML150-2S fixed speed compressor, an efficient unit when run fully loaded. The compressor has a high off-load (inefficient) characteristic. A ‘retrofit’ inverter was installed. No new compressor was required. Minimising capital cost. A reduction of 25% was achieved

AEROSPACE
Energy wastage due to incorrect purchase of plant. The system had a compressor that was purchased because it was ‘cheap’. An Ingersoll Rand N30K inverter driven compressor was installed. A 40% energy reduction was achieved

PHARMACEUTICAL MANUFACTURE
Energy wastage due to incorrect plant sizing and isolated systems. The primary system had grossly oversized plant and the secondary system was efficient but under utilised. The systems were linked and a coordinating control system was installed, to select the most efficient plant. A reduction of over 25% was achieved

BODYWORK REFINISHING
Energy wastage due to incorrect plant sizing and high heat load. The system has an over-sized compressor, resulting in high off-load operation. There was also an air conditioning unit in the plant room to reduce temperature. An Ingersoll Rand N11K compressor was installed eliminating off-load losses and enabling removal of the air conditioning unit.