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Customer case study
Eversfrank: optimising compressed air for printing
The Alzey customer report describes 30 percent energy savings after compressed air optimisation, combining central control, lower operating pressure and an adapted compressor combination.
Initial situation
Four compressors operated at high pressure and required frequent servicing. The existing control system did not adequately match the printing plant's changing demand, and machine operating states were initially difficult to assess.
Measures and implementation
Airleader with web connectivity was installed in mid-2016 and subsequently tuned. Visualisation revealed frequent idle-running cycles. A variable-speed compressor was later purchased and the combination adapted. Operating pressure fell from 9.5 to 7.2 bar.
Documented results
- Customer-reported energy savings
- 30% in the described project
- Operating pressure
- 9.5 bar before; 7.2 bar afterwards
- Idle running in the project summary
- Below 1%
- Control system payback
- One month from energy and service savings, according to the customer
How to interpret the figures
The 30 percent result applies to this project and is not an average across Airleader installations. The 2019 report describes several changes and does not include a complete normalised measurement series. Reported payback concerns the control system, not the full investment at another plant.
What this means for your station
Analysing operating states can reveal whether a different compressor combination or operating range is needed. Assessing another printing plant starts with its own demand profile and measurements.
Source and report date
Der Betriebsleiter 7–8/2019, S. 10–11. Original report by Martina Laun. This summary follows the original report; it is not a new measurement.
Assess your station's potential
Discuss the starting conditions, measurements and next steps with our team.