PET High Pressure Plastic Bottle Manufacture - Click here to learn more
A large PET plastic bottling company operating at 600 psi suffers from inconsistent product, high-energy cost and high annual compressor maintenance. The system operated with four Belliss-Marcom piston compressors all of which were rapid cycling without means of controlling. The header pressure and bottle blowing area fluctuated over 40 psig creating undesirable results.
Once the audit recommendation were installed including, rate of change automation, high and low pressure control storage, high and low pressure flow controllers the blow mold area varied less than 10 psig. The automation panel would make decisions based on how fast the pressure rises and falls in the control receiver, which allows air to be added removed without starting or loading an air compressor. The automation allows the system to wait until the last possible moment before making any decisions to load or start a compressor. Compressor power was reduced by 380 horse-power, totaling
$ 316,000.00 in annual energy savings.
Can Manufacturing Case Study/Testimonial - Click here to learn more
Air Perfection performed an audit at a local beverage can manufacture operating 1300 compressor horsepower on line. System pressure fluctuated > 27 psig as the compressors attempted to match the rapid changes in air demand created by the production equipment. The graphs in the document illustrate system pressure and compressor power during the audit.
Based on the audit recommendations, a variable speed drive compressor with additional control storage and a pressure flow controller were installed. The plant has saved over
$ 40,000.00 in power costs, holding the entire system pressure +/- 1 psig. The project investment was
$ 70,000.00 while their local utility company shared in a rebate program with $ 27,000.00 for a very attractive return on investment. The date coder has not tripped off
since the audit retrofit.
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