They achieved this by upgrading from an oil-injected air compressor system with an external heated desiccant dryer to an energy-efficient Atlas Copco oil-free variable speed drive compressor with an integrated heat of compression dryer.
As a food manufacturer, they needed to achieve certain compressed air quality standards, with no risk of contamination originating from the compressed air equipment and had been weighing up the pros and cons of an oil-injected compressor with filtration versus an oil-free air compressor.
The selected ZR 145 VSD compressor with an integrated MDG desiccant drum dryer now guarantees Class 2 pressure dew point-compliant air for both contact and potential contact with the food product. The iMDG dryer also has the added benefit of reduced power consumption and less filtration required to even further reduce energy usage.
Air audit gives detailed lifetime costs comparison
Whilst the lower upfront cost of the oil-injected system was tempting, an air audit showed in detail the long-term value of investing in an oil-free compressor and a heat-of-compression dryer with a guaranteed -40 degree ISO 8573-1-Class 2 pressure dew point, which consumes almost zero power and has a total power consumption always below 120W.
Significant savings were shown to come from a reduction in maintenance, oil changes and filtration, which not only reduces carbon footprint but also increases the system's efficiency without increasing risk. What's more, the integrated dryer saves space, which was important in the company's cramped plant room.
The investment payback time of an Atlas Copco ZR 145 oil-free compressor with integrated MDG dryer and energy recovery worked out to be under three years, meaning not only greater financial benefits but also the removal of any risk of product contamination.