The Vinyl Factory is the only pressing plant in the world running EMI 1400 presses and is on target to manufacture 1.8m vinyl records in this current financial year, as global demand continues to grow. Operating from 5am to 5.30pm, five days a week, the plant has relied on its CompAir variable-speed L37 RS compressor for the past four years, supplying high-quality, dry air for the various pneumatic devices and controls across the production facility.
As with all manufacturers, the business is experiencing significant energy price rises, as the wholesale price of electricity continues to escalate at an unprecedented rate. Managing energy performance across the facility is a key concern, so Adam Teskey, managing director for the Vinyl Factory called on Air Equipment to advise if the compressed air system could be optimised to deliver any efficiency savings.
Julian Higgs, Air Equipment area sales engineer manager explains: "The existing CompAir L37 RS compressor features a variable-speed motor, which matches air supply to precise plant demand, meaning there is no energy wasted while the compressor is idling, potentially saving up to 30% of the energy used by a similar-size fixed-speed machine. However, while the compressor itself is optimised for energy performance, our audit highlighted that there could be significant cost savings to be made by considering heat recovery options.
"As a general rule, only 10-20% of the electrical energy input to an air compressor is converted into useable energy. The remaining 90% is generated as heat and lost to the atmosphere as heat dissipated by the motor and cooling system. Recovering this excess heat and reusing it to warm areas of the production facility during the winter presented a real opportunity to save on gas usage and on heating bills.
"We therefore proposed an innovative air ducting system, working with our partner Maskot Projects, which would enable The Vinyl Factory to vent the hot air either outside during the warmer, summer months, or inside during colder weather. Operated manually, via two dampers, the system enables the company to simply divert the heat as and when required.
"Not only will this solution reduce heating energy bills. It also enables hot air to be diverted away from the compressor room and thereby reduce the ambient temperature. A compressor running at lower temperatures will be more efficient and more reliable, as there is less strain placed upon the working components. For example, the lubricating oil will have a longer life, the dryer will be able to operate more efficiently, and it can also reduce the amount of input energy to the compressor."
Current predictions are that the customer will be able to reduce its heating costs by circa £2,200 per year (at current prices) and this is likely to at least double as prices rise. Additionally, this is based on a requirement for heat 30% of the time. Clearly during colder spells, where the production areas require heat for longer periods, then the cost savings will increase significantly.
Teskey added: "Taking heat away from the compressor environment in the summer was just as important as reclaiming heat in the winter and we’re finding the new solution simple and effective to use. Plus, by lowering the ambient temperature, we'll be helping to prolong the life of the compressor too.