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Kingsmoor Packaging has increased production capacity and improved its energy efficiency in the process as a result of installing a GA90 VSD compressor from Atlas Copco. The decision provides KPL with the flexibility to meet future growth and follows an extensive plant operation review that included undertaking an iiTrak system energy audit.

KPL undertook a review of its plant operations with the aim of improving efficiency and, where possible, saving on costs. As KPL works manager, Dale Gunn, explains: “As a bespoke producer we rely on and take pride in our state-of-the art thermoforming equipment, which combined with our expertise in design, tool making and production, enables us to offer some of the most competitive plastic packaging products in the marketplace.”

To achieve this, KPL’s thermoforming process relies heavily on air movement with compressed air being available at the moulding stage. This is particularly relevant in pressure box techniques whereby the heated plastic material is formed onto a positive mould with the aid of air pressure. Although there were no major issues to address, it was felt that the compressed air system had been in use for a considerable time and “was in need of an upgrade in line with the latest developments in compressed air technology,” states Gunn.

Atlas Copco was called on to carry out an iiTrak system energy audit to check the load cycle profile for each compressor in KPL’s system. The goal of this exercise is to create a representation of the air and energy being used during a typical production week. This data monitoring exercise is then used to extrapolate an annual use of compressed air, the energy used and its cost.

The results of assessment revealed that the existing fixed-speed compressor rated at 110 kW and producing 333 l/s, was operating within a fluctuating pressure band of 1.60 bar. This meant the compressor was loading and unloading between 6.4 bar and 8 bar. Every time a compressor unloads it wastes energy while the motor is idling but the air inlet control is closed and the unit is not producing air*. A general rule is that for every 1 bar a compressor operates above the required pressure the system will potentially use 7 per cent more energy.

The recommendation was to install a 90 kW Atlas Copco GA90 VSD rotary screw compressor with air quality ancillaries. As the lead unit, this would match the variable production air demand in the region of 39-293 l/s and cope easily with the existing and anticipated demand. In practice, the company’s existing fixed-speed compressor was retained as back up and together with its dryer, receiver, oil water separator and pipework was re-sited from its warehouse location to the main compressor room to accompany the new GA VSD unit.

Atlas Copco Compressors

Atlas Copco Compressors is a leading manufacturer of energy efficient compressed air systems and vacuum pumps. In the UK the company offers a nationwide sales, service and distribution network and specialist compressed air advice and service to UK compressed air and vacuum users. Our product portfolio covers oil-free air compressors, oil-lubricated air compressors, centrifugal compressors, high-pressure compressors, vacuum pumps, blowers, engineered air and gas compressors, nitrogen generators; air treatment equipment such as dryers, receivers, and air line filters, as well as aluminium pipework for compressed air, nitrogen, oxygen and other gases.

Atlas Copco Compressors is a leading manufacturer of energy efficient compressed air systems and industrial gas generators. In the UK the company has a nationwide sales, service and distribution network to support compressed air and industrial gas users in all industries. Our product portfolio includes oil-free air compressors, oil-lubricated air compressors, air blowers, nitrogen and oxygen generators; air treatment equipment such as dryers, receivers, and filters, as well as pipework. We provide parts and service for any brand of air compressor and we can advise on energy efficiency, system optimisation and connectivity solutions.

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