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Bottling & Packaging Facility Reduces Operating Costs By More Than 29% And Shuts Down A Compressor
A California bottling and packaging manufacturer believed its air system operating costs could be reduced. While the air system pressure was elevated to prevent production shutdowns, it was also increasing operating costs, forcing multiple compressors to modulate, and causing the system pressure to fluctuate. The compressed air supply system was composed of two 75 hp and one 40 hp rotary screw air compressors, a refrigerated dryer and a coalescing filter.
1) THE QUINCY EQ RATING SYSTEM: Identified the potential for a >25% reduction in operating costs
The 2-hour EQ Rating survey identified the most significant cost reduction opportunities resulting from actively supporting the wide variations in air demand.
- Eliminate multiple modulated compressors
- Stabilize header pressure
- Reduce artificial demand and waste
2) THE QUINCY EQ ANALYSIS: Based on the EQ rating, the EQ Analyzer was installed to record system performance
A local EQ trained distributor installed the EQ Analyzer at the plant and collected critical system information.
- Data collected by the EQ Analyzer and the site information was then uploaded to the EQ Web Site.
- Patent-pending technology calculated existing performance of the system and modeled multiple system configurations to determine the optimal system solution.
- The results of the EQ Analysis indicated a QGV-150 variable speed compressor could support the wide variations in air demand and reduce operating costs.
3) THE EQ ANALYSIS REPORT: Calculated the ROI at <16 months for implementing the action plan
- A Quincy QGV-150 Variable Speed Compressor was installed to provide accurate control of system pressure.
- True PID Functions in the PLC controller adjust the speed of the Quincy QGV to match the rate of change in air demand.
- Remote Pressure Signal Connection overcomes the pressure drop created by air treatment equipment and stabilizes header pressure.
- With turndown capability of greater than 80%, the Quincy QGV performs as the trim compressor in all production conditions.
THE RESULTS: Operating costs reduced by more than 29% ($44,000/yr) and production shutdowns were eliminated
- The plant header pressure is now stable to within 2 psi vs. 20 psi before the system upgrades.
- The broad turndown range of the Quincy QGV compressor eliminates the need to operate any part-loaded, inefficient compressors.
- The original EQ System Rating took less than 2 hours and accurately predicted a >25% operating costs savings and an attractive ROI
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