Compressed Air Summit for Manufacturing Plants

The problem: An aging seven-compressor system with outdated controls, frequent cycling, unstable pressure and rising maintenance costs at a 281,000 sq ft automotive plant.

Published result: Three active compressors under one master controller; reported operating costs down 26%, from $1,277,394 to $941,959 (as reported by Atlas Machine & Supply).

Invited: Atlas Machine & Supply, with Hitachi Astemo · Read the published case

The problem: Several compressors loaded and unloaded together, ran unloaded, and plant pressure swung between 110 and 123 psi.

Published result: Over $50,000 and 589,121 kWh a year, pressure held near 112.5 psi, six-month payback (as reported by EnergAir).

Invited: EnergAir, with Whirlpool · Read the published case

The problem: Too much compressor horsepower online and unstable, high plant pressure at Subaru’s Lafayette, Indiana plant.

Published result: $88,965 and 2,120,625 kWh a year, confirmed with before-and-after amp readings; 2.7-year payback (as reported by Optimira Energy).

Invited: Optimira Energy, with Subaru of Indiana Automotive · Read the published case

The problem: Surging turbo compressors, a heatless desiccant dryer wasting purge air and a high pressure set point at a Utah packaging plant.

Published result: 933,791 kWh and $84,299 a year with a two-year payback; actual savings beat the projection by more than 20% (as reported by Atlas Copco and CH Spencer).

Invited: Atlas Copco and CH Spencer, with COMPAX · Read the published case

The problem: An EV battery manufacturer needed to cut the cost of making and drying its compressed air.

Published result: €60,000 saved a year after optimizing compressors and dryers with Extender+ (as reported by Atlas Copco; customer not named).

Invited: Atlas Copco

The problem: Many leaks and no measurable ultrasonic program at Caterpillar’s remanufacturing plant in Corinth, Mississippi.

Published result: Over $828,000 saved from air leaks alone over five years, with the site split into 11 survey zones (as reported by UE Systems and Amentum).

Invited: UE Systems and Amentum, with Caterpillar · Read the published case

The problem: A hard-to-find gearbox bearing fault, plus known air leaks and failing steam traps, and no tools to survey them efficiently.

Published result: Surveys identified $86,000 a year in air-leak losses and $175,901 in failed steam traps; the bearing was caught early enough to schedule the repair (as reported by UE Systems).

Invited: UE Systems, with BioKyowa · Read the published case

The problem: Corning’s Erwin, New York plant had no baseline of how it used compressed air.

Published result: 26 permanent flow meters and an ultrasonic survey found nearly 60 leaks; $85,400 a year if fully implemented, about two-year payback (identified; as reported by CHA Consulting).

Invited: CHA Consulting, with Corning · Read the published case

The problem: Undersized, restrictive piping with sharp turns caused a 10 psi pressure drop that kept a second 200-hp compressor cycling on at Donaldson's Frankfort plant.

Published result: Pressure drop eliminated, second compressor no longer needed; 447,180 kWh and $40,049 saved a year, verified with before-and-after air audits (as reported by Atlas Machine & Supply).

Invited: Atlas Machine & Supply, with Donaldson · Read the published case

The problem: Too much compressor horsepower online and unstable pressure at a Kraft Foods plant.

Published result: Controlled storage, corrected pipe sizing and a management system: $50,295 and 457,264 kWh a year, 1.7-year payback, confirmed by post-project trending (as reported by Accurate Air Engineering).

Invited: Accurate Air Engineering, with Kraft Foods · Read the published case

The problem: An undersized 3-inch copper header with crossing tees made compressors short-cycle at 110 psig.

Published result: Discharge pressure from 110 to 90 psig; energy from 1,152,072 to 571,400 kWh a year, $58,068 a year saved (as reported by Air Power USA, with Parker Transair pipe).

Invited: Air Power USA and Parker Transair · Read the published case

The problem: Open-tube blow-offs used for drying on nine die-casting machine lines.

Published result: 121 engineered nozzles: 1,465,879 kWh a year and an estimated $117,270 a year (as reported by Consumers Energy).

Invited: Auto-Cast, with Consumers Energy · Read the published case

The problem: Oil drained every 8,000 hours on two rotary-screw compressors.

Published result: Drain intervals beyond 24,000 hours, about 36 months; an estimated $5,780 in maintenance saved over three years (estimated; as reported by ExxonMobil).

Invited: ExxonMobil (Mobil SHC Rarus) · Read the published case

The problem: One oil-lubricated vacuum pump per press at Mar-Bal’s Ohio molding plant, with frequent service and press downtime.

Published result: Vacuum energy down 75%, 23 presses served with room for 10 more, less maintenance (as reported by Busch).

Invited: Busch Vacuum Solutions, with Mar-Bal · Read the published case

The problem: NovaTech Automation’s Bethlehem, Pennsylvania plant relied on an aging nitrogen generator for PCB soldering.

Published result: Faster start-up, a more reliable high-purity nitrogen supply and less solder dross with a modular i-Flow system (as reported by PEAK Gas Generation; no dollar figures published).

Invited: PEAK Gas Generation, with NovaTech Automation

The problem: Rising bulk liquid nitrogen costs, a rigid contract and supply interruptions at an electronics manufacturer.

Published result: Nitrogen cost from over $360,000 to about $90,000 a year, over $270,000 saved (as reported by South-Tek Systems).

Invited: South-Tek Systems, with Morey · Read the published case