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Customer case study
voestalpine: coordinating seven compressors
Four distributed stations, two compressor manufacturers and four variable-speed machines: the Birkenfeld customer report describes reduced idle running and maintenance after central control was introduced.
Initial situation
Seven compressors supplied the automotive components plant from four container stations. Before optimisation, the report describes idle running of 30 to 40 percent and pressure varying between 7.5 and 9 bar. Connecting the stations with pipework alone had not resolved the operating problems.
Measures and implementation
Airleader Master II was introduced in November 2019. TCP/IP converters connected the distributed stations through the existing company network. FU-Control integrated four variable-speed compressors. Visualisation and alarms supported monitoring, and measured data was also used for energy management.
Documented results
- Idle running
- 30–40% before; 2–3% after introduction
- Annual maintenance costs
- €21,000 before; €5,000 afterwards
- Network pressure
- 7.5–9 bar before; 7.6–7.7 bar afterwards
- Customer-reported payback
- Less than one year from energy and maintenance savings
How to interpret the figures
These figures are from the 2022 customer report and apply to this particular installation. The article does not provide a complete measurement series or a normalised comparison. The €16,000 annual difference concerns maintenance, not electricity alone. The Master II used at the time is not equivalent to a current model.
What this means for your station
For distributed stations, assess the pipe network, communications and operating ranges together. Several variable-speed compressors still need a coordinated station control strategy.
Source and report date
MY FACTORY 06/2022, S. 30–33. 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.