Case Study: Automotive Case One

A large automotive assembly plant with over 12,000 HP of air compressors was in the midst of a major expansion with a goal of increasing production and reducing their carbon footprint. 

The Paint, Stamping, and Assembly departments were the primary areas of focus, where current compressed air energy was unreliable and could not match the demand of upcoming production goals.

To first establish the current compressed air system capacity, a detailed compressed air audit was performed.  Once data was collected and analyzed, a custom plan to optimize the plant’s system was outlined and executed. After installing AirLogix PLC controls on five centrifugal compressors in one building and three new AirLogix PD’s on three rotary compressors in another building, a centralized AirMaster system was implemented to ease visibility and control on all compressors.

The control implemented in each manufacturing area of the plant introduced automated pressure regulation so that each area of manufacture could utilize the exact pressure needed and reduce artificial demand.

The result was a significant savings in energy costs, and a total reduction of the overall carbon footprint, exceeding the project goals.

Case Study: Automotive Case Two

A large automotive assembly plant was undergoing a major expansion. The existing plant relied on five 1200 HP Centrifugal compressors and one rotary screw compressor with plans to purchase and integrate an additional two large centrifugal compressors to their lineup.

Their existing compressors were functioning disjointedly and the plant wanted to gain better control of the compressors and their energy usage.

Case iZ installed new AirLogix control systems on the five existing centrifugal compressors and the two newly integrated centrifugal compressors. The two new compressors were installed in two major manufacturing areas of the plant, but tied together via a common header.

An AirMaster automation system was implemented and all of the compressors were integrated over the plant network.

The application of the new systems resulted in cohesive load sharing that ultimate produced an excess of 7MM lb of carbon emissions reduction.

Case Study: Automotive Case Three

A large automotive engine plant was looking for implementation of master controls for their compressed air system to simplify system regulation and reduce their carbon footprint.

Case iZ installed our innovative AirMaster technology as the central controller and AirLogix controllers with Air Density compensation to reduce compressor blowoff.

One key aspect of the system was to implement a boosted storage system to ride through peak demands during shift changes and meal times, preventing compressors from cycling on for short periods of time.  Peak demand management was also utilized to prevent large demand changes from the utility company.

The result of all new applications was a significant energy saving of over 1MM KWH, simplified compressed air system control, and a measurable reduction in carbon footprint emissions.

Case Study: Metals Case One

A large steel manufacturer was implementing a new caster operation and needed a new compressed air system to supply the new caster. In addition to utilizing two preexisting rotary screw machines, the plant purchased four new 1500 HP centrifugal machines for the caster operation.

The caster operation would have varying demands and likely times that there would be significant blowoff and wasted air.  AirLogix controllers were implemented on the centrifugal machines, utilizing the Case DTL algorithms to minimize blowoff. 

While some minor blowoff was still present, excess air available on the caster side could be utilized for plant air and thus keep the rotary screw machines offline.

A crossover valve was implemented to allow the two headers to be managed together.  This would allow excess capacity in the Caster Air System to be utilized for plant utility air, thus minimizing the waste.  The AirMaster system and AirGate software allowed for the optimal scenario to be utilized, significantly reducing energy usage while improving the overall reliability of the system.

Case Study: Metals Case Two

A large aluminum can manufacturer had multiple compressors in two separate locations of the plant; three centrifugal machines in one room and two centrifugal compressors and a spiral valve rotary screw in another. 

Their existing compressors originated from three different OEM manufacturer.  Despite doing some OEM based upgrades, the plant still had large pressure swings and a lot of wasted blowoff air on the centrifugal compressors.

Case iZ performed a thorough compressed air audit and identified several areas for improvement. One of those recommendations that was implemented was new compressor controls and system automation.  The compressor blowoff was eliminated and wasted energy was significantly reduced.

They were also able to turn off at least one compressor, which allowed increased capacity to meet more production volume seamlessly.