KITCHENER AUTOMOTIVE MANUFACTURER
A manufacturer of automotive foam components located in Kitchener, Ontario, engaged SMARTCAir to improve the compressed air system efficiency in its plant. The facility ran a complex setup of multiple compressors to supply air for a 24/7 operation (production 5 days a week). The objective was to reduce energy costs and streamline the system, as compressed air was identified as a significant utility expense for the plant.
Current Issues
Many Compressors in Operation:
Inefficient Load/Unload Cycling:
Inefficient Load/Unload Cycling:
The audit revealed the plant had eight (8) air compressors in the system, with all units running during production shifts except one. Typically, the system delivered between 3,000–4,000 CFM on an hourly basis to the plant. The compressors included a mix of types and sizes (e.g., one was a 60 hp VSD that ran continuously). One 150 hp compressor (Kaeser DSD 150) was actually not needed at all – it never turned on even at peak demand, indicating the system had more capacity than necessary.
Inefficient Load/Unload Cycling:
Inefficient Load/Unload Cycling:
Inefficient Load/Unload Cycling:
In the base case, many compressors were loading and unloading frequently rather than operating steadily. About 30% of the time, the specific power spiked above 20 kW/100 CFM due to multiple machines partially loaded. Essentially, rather than one or two units running at optimal efficiency, several were running at less efficient points. This led to a high average specific power (~19.7 kW/100 CFM) and wasted energy whenever compressors ran unloaded (idling but still consuming power).
High Energy Cost:
Pressure Maintenance Issues:
Pressure Maintenance Issues:
The annual electricity spend for compressed air was estimated at $559,000, roughly $2,100 per production day – a huge operating cost. Much of this was due to the inefficiencies noted. With a blended rate of ~$0.135/kWh, the system was using over 4 million kWh/year on compressed air alone.
Pressure Maintenance Issues:
Pressure Maintenance Issues:
Pressure Maintenance Issues:
To keep up with demand fluctuations across the plant, the system pressure was maintained at a relatively high level. Some compressors were kept running as “trim” even when not needed, just to maintain pressure. This strategy ensured air supply but at the cost of efficiency. Additionally, having so many pieces of equipment increases the risk of something failing or needing maintenance at any time, which could jeopardize pressure if not well-coordinated.
Proposed Solution
Consolidation of Compressors (Reduced to 4):
The recommendation was to shut down or remove half of the compressors. The system would be reconfigured to operate with just four compressors instead of eight. This typically involved retiring older, less efficient units and possibly introducing one new high-efficiency compressor. By concentrating load on fewer machines, each could run in a more efficient range (nearer to full load) instead of many running at part load. Notably, the underutilized 150 hp compressor was slated for removal, and other small units that only added marginal capacity would be taken offline.
Introduce a VSD Trim Compressor:
A new or existing variable speed drive (VSD) compressor was designated as the “trim” machine to modulate according to real-time demand. This VSD unit would handle fluctuations in airflow smoothly, eliminating the need for multiple compressors to turn on and off. The other remaining compressors (likely fixed-speed) would operate as base load, running at full capacity during production. When demand dips (e.g., during breaks or lower usage periods), the VSD would slow down, and some base compressors could be turned off entirely. This approach ensures no compressor is running unloaded.
Optimize Control Strategy:
SMARTCAir implemented a modern control system to sequence the four compressors. It ensured that during production, compressors are staged so that either three or fewer machines cover the load, with the VSD adjusting output, and the fourth unit is off or in standby. In non-production hours, most compressors turn off, and the VSD unit maintains pressure for the lower loads (which mainly consist of leaks or minor uses). The controls also prevent the scenario of two similar-sized compressors running simultaneously at low loads – instead one turns off while the other carries the load efficiently.
Leak Reduction and Removal of Unnecessary Equipment:
During the assessment, about 60 CFM of leaks were estimated in the system (particularly since non-production flow was 60–80 CFM). The plan included a leak repair initiative to cut this wasted flow. Additionally, the idle Kaeser compressor was physically isolated or removed to simplify the system. Less piping and fewer active connections also reduce potential leak points.
Savings
Energy Savings:
Emissions Reduction:
Energy Savings:
The optimized system achieved roughly 8.5% reduction in annual energy consumption for compressed air. This corresponds to about 350,000 kWh of electricity saved per year. While the percentage may seem modest compared to some other projects (because this project was more about consolidation than major equipment replacement), it is a considerable amount of energy in absolute terms.
Cost Savings:
Emissions Reduction:
Energy Savings:
The energy savings translated to about $47,700 in annual cost savings on electricity. The plant’s compressed air electricity bill fell from ~$559k to around $511k per year. In addition, by halving the number of active compressors, the plant likely saved on maintenance costs (fewer oil changes, filter replacements, repairs, etc., for four machines instead of eight).
Emissions Reduction:
Emissions Reduction:
Improved Reliability:
Given Ontario’s relatively low-carbon electricity, the direct CO2 emissions reduction was small in tonnage – approximately 3.4 tonnes of CO2e per year avoided. However, from an efficiency standpoint, the improvement is meaningful and any reduction in emissions is positive. Moreover, this project enhances the plant’s ability to further reduce emissions if the electricity grid becomes greener or if they pursue more leak repairs.
Improved Reliability:
Improved Reliability:
Improved Reliability:
With a leaner set of compressors, each is more consistently loaded, which generally improves reliability. The compressors no longer cycle on/off as frequently, reducing mechanical stress. The removal of redundant units also simplifies the system, making it easier to monitor and maintain. The remaining four compressors can be rotated for maintenance without risking pressure loss, and the new control ensures backup is available if one goes down.
Incentives:
Improved Reliability:
Incentives:
The project qualified for an energy efficiency incentive of about $101,000 from local utility programs. This incentive helped offset the cost of the new controls and any new compressor purchase, making the payback on the project even more attractive.
Conclusion
SMARTCAir’s intervention at this automotive foam component manufacturing facility resulted in a streamlined compressed air system that uses fewer compressors to do the same work more efficiently. By consolidating eight compressors down to four and implementing advanced control with a variable speed unit, the plant cut its energy usage by over 8%, saving nearly $50k annually. The compressed air supply is now more stable and easier to manage, with less risk of unexpected downtime or pressure issues. This case demonstrates that even in a plant with modern equipment, there’s often room to improve by eliminating inefficiencies and right-sizing the system. Our customer benefited from lower operating costs, a sizable utility rebate, and a step forward in sustainability by reducing its carbon emissions – all while maintaining the air power needed for production.
SMARTCair
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