Compressed Air Best Practices - March 2008 - (Page 23)

Focus Industry FOOD PROCESSING | 03/08 | Recommendation #3: Use Buffer Room Compressor as Back-Up and Fix Dewpoint The stand-alone 100 hp oil flooded rotary screw compressor is located in the Buffer room. The compressed air from the 100 hp does not meet Midwest Bakery standards because of the +40 dewpoint refrigerated dryer. We found the air to be completely saturated and the air is of very poor quality. The main air dryers in the plant are all regenerative twin tower -40 PDP dryers. The plants’ air quality will significantly increase if all the compressed air supply is dried by the regenerative type air dryers. With the improvements outlined in step one — implementing compressed air management — the 100 hp can be relegated to back up duty only. Recommendation #4: Install Low-Pressure Blowers for Blow-Off Applications Compressed Air Treatment SPECIALISTS Manufacturing innovative compressed air solutions since 1959, ZEKS’ expertise in compressed air treatment has enabled companies of every size to minimize energy cost, optimize production and improve air system reliability. Most of the lines at Midwest Bakery incorporate low-pressure blow off of the product using air knives. This represents a significant opportunity for savings. We recommend detailed testing to properly size low-pressure centrifugal blowers to convert these applications from high-pressure air. The air knives at a 10 psig setting consume an estimated 418 cfm of compressed air. We recommend low pressure centrifugal blowers be adapted to provide this air because any time you compress air to 100 psig to use it at 10 psig, energy is wasted. Any place the plant is blowing compressed air on a continuous basis where high-volume and low-pressure is required, the power required to operate a centrifugal blower is less than 10% that of using high-pressure compressed air. Recommendation #5: Manage Air Leaks • Refrigerated Dryers • Desiccant Dryers • Filtration • Flow Control COMPRESSED AIR SOLUTIONS ® The leakage estimate at Midwest Bakery is typical to other facilities in your industry and the plant would benefit from a semi-annual leak review to keep the leakage rates below 5% of average demand. The plant can purchase a detector for $2,500 or have PSI provide the service. Recommendation #6: Improve Performance of Condensate Drains We recommend zero loss drain valves be installed on the compressor after coolers, separators and on the filtration to remove oil. The wet receivers should also have a zero loss drain installed. These drains are very high quality and very reliable to ensure proper drainage without wasting compressed air. The air system generates 436-gallons per 24-hours and this water must be removed from the system. Conclusion Midwest Bakery implemented most of the corrections and solutions offered by Power Supply Industries. Today, Midwest Bakery has completed the expansion and still operates less rotary screw air compressor horsepower than when the audit began by eliminating inappropriate uses and implementing compressed air management practices. For more information please contact Jim Timmersman, Power Supply Industries, tel: (314) 277-1777, email: jim.timmersman@psiind.com, www.psiind.com To discuss your compressed air requirements with a ZEKS Specialist, or for the name of the Authorized Distributor nearest you, contact us: 800-888-2323 www.zeks.com © 2008 ZEKS Compressed Air Solutions CABP www.airbestpractices.com 23 http://www.zeks.com http://www.psiind.com http://www.zeks.com http://www.airbestpractices.com

Table of Contents Feed for the Digital Edition of Compressed Air Best Practices - March 2008

Compressed Air Best Practices - March 2008 Contents From the Editor Utility-Air News The Compressed Air Audit of the Month: Saving Energy with Blowers in Canada Do You Provide World-Class Service? Managing Rotary Screw Air Compressors at Midwest Bakery The Difference Between Acfm and Scfm for Proper Vacuum Sizing Best Practices — Multi-Module Process Air Dryers The Vacuum Formation Process in Building Compressed Air Filter Elements Solberg Manufacturing Real World Best Practices: Measuring Pressure Dewpoint in a Compressed Air System Resources for Energy Engineers: Training Calendar & Product Picks Wall Street Watch Advertiser Index Job Market

Compressed Air Best Practices - March 2008

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