Compressor controller reduces energy costs

Operators of multiple compressors can achieve significant energy savings thanks to the Ingersoll Rand X-Series System.

According to CAPS Australia (Compressed Air and Power Systems), the Australian distributor for the X-Series, it eliminates waste by managing up to 12 positive displacement compressors simultaneously. This includes compressors of different capacities, different types (fixed speed, variable speed and variable capacity), and in any combination and configuration.

“As much as 20-60% of the energy used to operate compressed air systems in manufacturing, industrial and other sectors is wasted because users often operate more compressors than necessary, operate the wrong combination of compressors or maintain an elevated system pressure,” explained Greg Baldwin, National Sales and Export Manager for CAPS.

“If you are using multiple compressors, the X-Series can provide you with greater efficiency, reliability and tremendous costs savings,” added Greg.

By using advance control functionality, the X-Series brings standby compressors online incrementally during peak periods of demand. It also manages the compressed air system at the minimum required pressure without compromising air supply reliability.

In addition, by dynamically matching the most energy-efficient compressor or combination of compressors to the compressed air demand, the series delivers maximum efficiency while helping to reduce power costs.

It automatically selects the best-fit capacity to suit the demand pattern and prevents excessive cycling that can result in poor compressor efficiency as well as increased maintenance.

Specsavers, the world’s third largest optical chain and a fast-growing concern in Australia, recently installed an X-Series as part of its continuous improvement program.

“As production increased in Australia, we went from using one compressor to using three and our electricity costs escalated. We were keen to reduce our electricity consumption by installing a compressor controller,” said Peter Kennedy, Specsavers’ Project Manager. “CAPS made us aware of the new X-Series and that it could significantly reduce our energy as well as maintenance costs. It links all our compressors together and makes them ‘talk’ to one another to ensure that they never run using more energy than necessary. This will allow us to save about 10% on our power costs, which in turn means a corresponding reduction in greenhouse gas emissions,” said Peter.

For added user convenience, the system also ensures that the three compressors run an equal number of hours so that servicing for all of them is always required on the same day.

“We are always looking for ways to reduce our costs and our environmental footprint; this is a simple, off-the-shelf product that makes a big impact. Our effectively managed compressed air system will now lower our maintenance costs, reduce compressed air downtime, increase our production output and improve our overall product quality,” he concluded.