BRICK MANUFACTURING PLANT
A large brick manufacturing plant partnered with SMARTCAir to analyze and improve its compressed air system. The plant was facing soaring energy costs for compressed air and suspected that its compressor configuration was inefficient. SMARTCAir conducted a detailed study to uncover the issues and recommend solutions that would save energy and stabilize the air supply for the brick production process.
Current Issues
Dual Compressors Running Inefficiently
Dual Compressors Running Inefficiently
Dual Compressors Running Inefficiently
The facility’s base case had two main compressors (one with a modulation control and one fixed-speed) operating together. For most of the time, a single “Energy Saver” compressor managed the load alone. However, whenever a short peak demand (~1,400 ACFM) occurred, it triggered the second compressor to start. After the peak, instead of one machine turning off, both compressors remained running at part load, when only one was truly required. This scenario led to prolonged periods of inefficient operation with two half-loaded machines.
Excessive Energy Waste
Dual Compressors Running Inefficiently
Dual Compressors Running Inefficiently
Because of the above, the system’s specific power (energy per unit of air) was high – about 34.2 kW per 100 ACFM in the base case. Essentially, the plant was often using twice the horsepower needed to supply its average airflow. This resulted in unnecessary electricity consumption and higher utility bills.
Pressure Fluctuations
Pressure Fluctuations
Pressure Fluctuations
The dual-compressor overlap caused pressure control issues. The system pressure was set high (around 115 psig) to avoid dropping too low during peaks. Still, when both compressors kicked in, pressure would overshoot, and when they idled, pressure dipped. One recorded low-pressure event went down to ~100 psig, which could disrupt sensitive equipment. These swings indicated the distribution system might have bottlenecks and that the control strategy wasn’t keeping pressure stable.
Undersized Piping
Pressure Fluctuations
Pressure Fluctuations
Analysis suggested the plant’s piping might be undersized or lacking a loop. This could cause the distant points of use to see lower pressure during high flow, prompting operators to raise the compressor output pressure as a band-aid. Such a practice increases energy consumption further.
Proposed Solution
Cascade Control with Increased Storage (Model “A”):
The primary recommendation was to reconfigure the system to use two fixed-speed compressors in a proper cascade with a substantially increased receiver volume. In practice, this meant running one compressor (Atlas Copco GA 132, ~177 hp) as the lead machine, and bringing in the second compressor (GA 110, ~150 hp) only when airflow demand exceeds the first unit’s capacity. To enable this, the plant would add about 3,800 gallons of receiver capacity – a big air storage buffer. The extra storage smooths out short spikes in demand, so the lead compressor can handle them without immediately needing help. The second compressor now cycles on only for genuine peaks, and turns off when not needed. This proper sequencing and buffer eliminated the inefficient scenario of both running together for long durations.
Optimized Setpoints:
Along with new controls, SMARTCAir adjusted the pressure setpoints. With more storage and better control logic, the system could maintain a lower average pressure (around 108 psig instead of 115) while still meeting production needs. Every 1 psi reduction yields ~0.5–1% energy savings, so this helped reduce energy use. The main compressor operates mostly fully loaded (its most efficient state), and the second unit only tops up pressure when the line pressure dips near a threshold, then switches off.
Optional VSD Upgrade (Model “B”):
As a future consideration, SMARTCAir evaluated replacing both compressors with a single larger variable-speed drive compressor (an Atlas Copco GA 200 VSD, ~300 hp) plus a moderate 2,000-gallon receiver. This setup could dynamically adjust to demand and potentially achieve even greater energy savings (estimated ~53% reduction in energy use). However, it would require significant capital investment. The plant decided to first implement the cascade control solution using existing-type machines (Model A), which captured the bulk of the savings without the cost of a brand-new VSD compressor.
Savings
Energy Savings:
Emissions Reduction:
Energy Savings:
The optimized two-compressor cascade system reduced compressed air energy consumption by about 41%. In real terms, the plant saved roughly 1.06 million kWh per year compared to the previous setup. This is energy the plant no longer has to buy, significantly lowering its utility usage.
Cost Savings:
Emissions Reduction:
Energy Savings:
The energy reduction translated to approximately $148,000 in annual electricity cost savings for compressed air. The plant’s yearly air system power cost dropped from around $360k to about $212k after the changes. These savings go straight to the company’s bottom line and will continue accruing every year.
Emissions Reduction:
Emissions Reduction:
Improved Performance:
By cutting energy waste, the facility also cut its carbon emissions by about 41%. This is a substantial environmental benefit – for context, if the plant is in a region with a moderately clean grid, this could be on the order of 100–150 fewer tons of CO2 emitted per year.
Improved Performance:
Maintenance and Reliability:
Improved Performance:
The new configuration eliminated the problematic pressure swings. The system can now handle peak air demands without dropping below safe pressure levels, and without having to overcompensate by running two compressors all the time. Pressure is steadier and kept closer to the optimal setpoint. This results in more consistent air tool performance and potentially higher product quality (no pressure-related defects in forming the bricks).
Maintenance and Reliability:
Maintenance and Reliability:
Maintenance and Reliability:
With one compressor shouldering most of the load (and doing so efficiently), the second compressor runs far less frequently. This reduces maintenance needs and extends the service life of both units. The system also inherently has backup capacity – if one compressor is down for service, the other can cover more of the load in the interim, thanks to the large receiver, improving reliability.
Conclusion
Through SMARTCAir’s expertise, the brick manufacturer transformed its compressed air system into a much more efficient and reliable utility. The adopted solution of smarter controls and more storage slashed energy usage by over 40% and saved the plant roughly $150k per year in power costs. These savings were achieved without purchasing an entirely new compressor, showcasing that optimization and better system design can unlock huge value. Additionally, the plant’s operators now enjoy steadier air pressure and a simpler control scheme, all while significantly reducing the facility’s carbon footprint. This case highlights SMARTCAir’s ability to deliver both economic and operational benefits in industrial energy systems.
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