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Customer case study
FreiLacke: connecting two compressed air stations
Six fixed-speed compressors with a combined 300 kW supplied two plant areas. The report documents a combined programme of network connection, central control, pressure reduction and leak reduction.
Initial situation
Liquid and powder coating production had separate stations. The report describes idle-running costs above 30 percent, network pressure of 8.5 bar and specific energy consumption of 0.16 kWh/m³. Electricity and air measurements established the comparison baseline.
Measures and implementation
A compressed air pipe connected the two stations and Airleader was installed in 2011. Existing compressors then supplied demand in staged combinations. Pressure and leakage were also reduced. The building management system provided the 2016 comparison data.
Documented results
- Specific energy consumption, 2016 actual figures
- 0.113 kWh/m³ compared with 0.16 kWh/m³ before
- Network pressure
- 6.5 bar compared with 8.5 bar before
- Idle-running cost share, 2016 actual figures
- Below 3% compared with over 30% before
- Reported cost comparison
- €170,000 savings comparing 2010–2016 with 2005–2010
- Total investment and payback
- €65,000 for pipework, installation and control; 2.3 years according to the report
How to interpret the figures
Savings relate to the full improvement programme and cannot be attributed solely to the controller. Periods and figures are customer statements in the 2017 report. Further improvements described in the article are not mixed with the 2016 actual figures in this table.
What this means for your station
Reliable performance indicators require electricity and produced air volume to be measured together. Evaluate network connection, control and pressure on a consistent data basis.
Source and report date
Der Betriebsleiter 11–12/2017, S. 2–4. 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.