Over the last few months I’ve covered many key factors to consider when it comes to reducing your compressor’s energy usage and optimising its performance. Sometimes it can be difficult to imagine how you can implement these ideas and technology into your own systems, so in this article I’ll be giving you a real-world example.
BOGE works with many manufacturers from across industry. Recently, that included famous British manufacturer of bathroom fixtures and plumbing supplies, Armitage Shanks.
The firm produces more than 1,500 toilets a day, along with other bathroom ceramics, such as basins and bidets, at its factory in Rugeley, Staffordshire. Following the installation of extra manufacturing plant, which resulted in compressed air demand increasing by around 30%, BOGE and its Platinum Partner Aroplus (UK) were called in to review the existing compressed air system and provide support to ensure Armitage Shanks’ compressed air needs are met.
The process began with a data logging exercise of the existing system. This revealed that the two fixed speed compressors used to manufacture basins, toilets and other sanitary ware weren’t operating as efficiently as required. Given that they were ageing, the logical option was to invest in a more advanced, efficient system that would future-proof manufacturing for the foreseeable future.
Aroplus recommended that Armitage Shanks install a system comprising a BOGE SLF 271-3 200kW frequency-controlled air compressor, a BOGE S220-3 160kW fixed speed air compressor, and the BOGE Airtelligence control system.
The BOGE SLF 271-3 is a direct-coupled, oil-lubricated screw compressor with frequency control offering high air delivery and outstanding energy efficiency. It can also incorporate heat recovery for further energy savings.
The compressor features a multi-functional suction regulator, which closes hermetically, preventing oil vapours from escaping. A fully unloaded start boosts energy savings and, in the event of a fault, the regulator automatically closes, ensuring intrinsically safe operational reliability.
The unique BOGE air ends allow high free air delivery with a low power requirement, ensuring a reliable and efficient compressed air supply. The BOGE Focus 2.0 control, with RFID card entry, effective oil separation and long-life component parts guarantee optimum energy consumption and cost-effectiveness.
Meanwhile, BOGE Airtelligence manages the compressed air system to ensure the best possible operating efficiency, monitoring the entire range of compressor functions both locally and remotely to assure profitable and effective production output.
The Airtelligence controls every compressor in a multi-compressor system by selecting the ideal compressor or multiples of compressors to match the system demand based on air consumption. Moreover, Airtelligence intelligently forecasts additional or reduced demand and automatically switches priorities to optimise the combination of compressors running at any one time.
As you can see, each and every component within the system serves a valuable purpose, which contributes to better overall performance, ensures Armitage Shanks needs were met, and at lowering operating cost through enhanced efficiency. This approach is used for every customer we work with, to guarantee they get the right system for their requirements.
The result of Armitage Shanks installing this new system has been a 27% reduction in energy costs and an impressive 29% cut in maintenance costs, as well as carbon emission savings of around £3,500 a year. And crucially, the system was installed with minimal disruption to production and no hassle.
You can learn more about improving compressor efficiency and slashing costs with these free to download resources: https://uk.boge.com/en/whitepaper.