The manufacturer partnered with Elgi Compressors to upgrade, optimise and enhance the energy efficiency of the compressed air system at its plant in Bretagne, France. This was achieved by adding new units from the Elgi EG Super Premium (SP) Series equipped with an integrated heat recovery system (HRS).
The partnership began at the end of 2023, when the customer tasked Elgi and its French Channel Partner, Rubix, with expanding and upgrading its existing compressed air system. The project initially included the installation of an Elgi EG132PV air compressor, an HRS system, and a master controller to optimise the entire compressor room. By recovering heat that would normally be wasted, customers could reduce their building's heating costs and contribute to their sustainability goals.
Pascal Daniel, sales manager at Rubix, commented: "Shortly before commissioning the first ELGi EG132PV, we encountered a major breakdown on a 132 kW compressor from another brand. This led us to work with our client to develop a project plan to maximise the efficiency of their compressed air system."
Elgi and Rubix conducted a comprehensive audit of the compressed air plant and the compressed air distribution network. "Following the audit, we partnered with the client and Rubix to focus on two key areas for major energy savings — upgrading the compressed air network with a 1 bar pressure reduction and installing a highly efficient 90 kW two-stage compressor with integrated heat recovery. A Master Controller was also implemented to optimize energy use across the system", reported Stéphane Morvan, sales manager, Western France at Elgi.
The key benefits of adopting Elgi's advanced air compressor technologies include:
· Energy Savings – An annual reduction of 322,636 kWh, resulting in an estimated annual cost savings of €32,263.
· Reduced Carbon Footprint – Estimated annual savings of 199,389 kg CO₂, contributing to a more sustainable operation.
· Enhanced Efficiency – EG Super Premium Series air compressors delivering up to 15% greater energy efficiency compared to previous models, significantly reducing energy consumption.
· Optimised Operations – The Master Controller manages and optimises the entire compressor room, delivering an expected return on investment (ROI) within 12 months.
· Sustainable Practices – The Heat Recovery System (HRS) repurposes waste heat, reducing reliance on additional heating equipment while lowering CO₂ emissions.
"Reliability, efficiency, and optimisation of the compressed air system have been essential for the customer to maintain their operations at peak productivity levels. The combination of our compressors and Heat Recovery System (HRS) significantly reduces power consumption, emissions, and operational costs. Additionally, the Master Controller ensures seamless system performance and long-term cost efficiency, while the ongoing service and maintenance maximises the uptime and reliability," - said Nils Blanchard, regional manager – Benelux & France at Elgi.
The Elgi EG SP Series is said to deliver energy efficiency gains of up to 15% within the 75-160kW compressor range. These machines feature newly configured two-stage airends with Elgi’s η-V profile, optimising the compression process to achieve substantial reductions in specific power consumption.
Designed with low-speed airends and a lighter load per stage, the EG SP Series is claimed to ensure an extended component lifespan, reducing maintenance demands and operational costs. Equipped with IE4 motors, these compressors integrate advanced design and technology, further enhancing energy efficiency. Additionally, each unit is fitted with the Neuron 4 industrial controller, guaranteeing optimal performance and user-friendly operation.
The EG Super Premium Series also boasts an oil filter with an extended 4000-hour lifespan, ensuring superior filtration and durability. With an oil carryover of under 1ppm, the EG Super Premium Series is environmentally friendly, with one of the lowest levels of emission into the atmosphere.