Pipework choices save Sharpak Aylesham thousands in energy 22 May 2013

Rigid plastic packaging manufacturer Sharpak Aylesham says it expects substantial operational savings from new compressed air and chilled water systems, installed at its new thermoforming facility in Kent.

As part of its £1.5 million production relocation plan, the firm contracted energy-saving specialist IsoCool to replace its ageing pipework system with an extensive stainless steel infrastructure.

Nigel Hallett, managing director of IsoCool, explains that the firm's previous was consuming some 11GW of energy annually, of which 31% was required to run the compressors and chillers. Even the smallest leak was wasting considerable energy.

Relocating the site, he says, was deemed a far more efficient solution than refurbishment, and hence the project.

"The objective for Sharpak was to create an industry-leading production facility, which required all elements of the build and relocation to run perfectly," states Hallett.

IsoCool, he says, designed a bespoke turnkey solution, which included a compressed air ring main, plus flow and return chilled water headers, each with high- and low-level valved outlets.

The chilled water pipework was insulated with foil-faced phenolic foam sections to reduce thermal losses, and some of the existing steel framework in the building was re-used to support the new pipework, to minimise the project's carbon footprint.

To maximise the longevity and efficiency of the pipework, IsoCool also fabricated the system in thin-wall stainless steel tube, a material that avoids many of the problems associated with galvanised steel.

"Rust and corrosion can cause problems in galvanised steel pipework, as it has to be cut and threaded," comments Hallett.

"Sharpak also uses oil-free air in its compressed air system, and this is much more susceptible to corrosion than lubricated compressors," he adds.

"Stainless steel resists corrosion far better than galvanised steel, and is particularly suitable for large-diameter pipework and low-pressure, oil-free air. It's also much lighter for the same pressure and temperature rating, and installs very well when welded and purged."

Hallett says that Sharpak Aylesham has closely monitored the site's electricity consumption since moving and that, even at this early stage, it's easy to see the difference made by that the new pipework.

He quotes figures in the "thousands of pounds" in terms of energy saving from the new pipework, as well as "a reduction in maintenance and repair costs".

Brian Tinham

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IsoCool

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