TORONTO CUSTOM CABINETRY
A Toronto-based manufacturer of custom cabinetry engaged SMARTCAir to evaluate its compressed air system. The company’s goal was to cut energy costs and eliminate waste in its aging compressor setup. SMARTCAir performed a comprehensive assessment to recommend improvements that would make their air system leaner, more reliable, and more cost-effective.
Current Issues
Two Large Compressors Running Continuously
High Specific Power (Inefficient Operation)
High Specific Power (Inefficient Operation)
The custom cabinetry company’s base system consisted of two 100 hp fixed-speed air compressors. Both machines were running in tandem even when demand was low – typically only 200–300 CFM was needed for production on average, a load that a single compressor could handle. This meant one compressor was essentially excess most of the time, leading to gross inefficiency.
High Specific Power (Inefficient Operation)
High Specific Power (Inefficient Operation)
High Specific Power (Inefficient Operation)
Because two half-loaded compressors were doing the work of one, the energy intensity was extremely high. The audit found a specific power of ~64.7 kW per 100 CFM of air produced in the base case. This is more than triple a reasonable benchmark, indicating a lot of wasted electricity for the air being delivered.
Unnecessary Idle Running
Adequate Pressure but Poor Control
Adequate Pressure but Poor Control
The control scheme had both units cycling between load and unload, never shutting one down. As a result, even when air demand was moderate, two compressors drew power (one heavily loaded and the other partly loaded or idling). This not only wasted energy but also put needless hours on the equipment.
Adequate Pressure but Poor Control
Adequate Pressure but Poor Control
Adequate Pressure but Poor Control
The system could maintain pressure (with peak flows up to ~570 CFM for short bursts), but it was doing so in a very uneconomical way. There was no variable capacity control to trim output — it was either on or off for these big compressors, leading to pressure overshoot and blow-off during low demand.
Proposed Solution
Replace Two Fixed-Speed Compressors with One VSD Compressor:
The core recommendation (Model “A”) was to install a single 125 hp variable-speed drive (VSD) compressor to handle the entire load. A modern VSD unit can ramp its output up or down to match demand, which allows it to run one compressor at optimal efficiency across the plant’s full range of air usage. This immediately eliminates the inefficiency of running two motors when one will do.
Retire or Reassign Inefficient Units:
By removing the two older 100 hp fixed-speed machines from primary operation, the plant avoids their poor part-load efficiency. One of the old compressors could be kept as an emergency backup, while the other could be taken out of service. This ensures redundancy for reliability but prevents the inefficient overlap in normal operation.
Tighter Pressure Control:
The new VSD compressor maintains system pressure with far less fluctuation. It can hold the required pressure with “tighter” control, meaning reduced need to over-pressurize the system. This leads to less artificial demand (air use that scales with higher pressure) and further energy savings. Operators can likely even lower the target pressure slightly once the VSD is in place, without seeing pressure drops during peak periods.
Alternate Option – Dual Compressor Model:
SMARTCAir also tested an alternate scenario with two new 100 hp fixed-speed compressors (Model “B”). While simpler, this option yielded lower savings (~44% vs 69% with the VSD). Our customer ultimately favored the single VSD approach for maximum long-term savings and performance.
Savings
Energy Savings:
Emissions Reduction:
Energy Savings:
Approximately 69% reduction in compressed air energy consumption. This translates to over 500,000 kWh saved per year. The new single-compressor system uses only about one-third of the electricity that the old two-compressor setup required.
Cost Savings:
Emissions Reduction:
Energy Savings:
About $68,400 in annual electricity cost savings (at $0.135/kWh). The company’s air system electric bill drops from roughly $100k per year to around $31k per year – a dramatic decrease that improves the facility’s bottom line.
Emissions Reduction:
Emissions Reduction:
Incentive Eligibility:
Nearly 69% lower greenhouse gas emissions associated with the compressed air system. This is equivalent to eliminating roughly two-thirds of the CO2 output, aiding the client’s sustainability targets. (For context, in Ontario this reduction might be on the order of 15–20 tons of CO2 annually, given the province’s relatively clean electric grid.)
Incentive Eligibility:
Incentive Eligibility:
Incentive Eligibility:
The project qualified for an estimated $114,600 utility incentive due to the significant energy efficiency gains. This rebate helps offset the capital cost of the new VSD compressor and ancillary changes, improving the project’s return on investment.
Operational Benefits:
Incentive Eligibility:
Operational Benefits:
The new setup is simpler and more reliable – one compressor doing the job of two means less maintenance and easier monitoring. The VSD’s smoother operation also leads to better product quality (no pressure drops affecting air tools) and a quieter, cooler compressor room.
Conclusion
SMARTCAir’s assessment enabled this custom cabinetry company to transform an outdated compressed air system into a model of efficiency. By consolidating to a single right-sized VSD compressor, our customer slashed its compressed air energy usage by roughly 70%, saving tens of thousands of dollars each year. This upgrade not only cut operating costs dramatically but also reduced the company’s carbon footprint and qualified for significant energy rebates. In summary, the facility now enjoys a stable air supply with improved pressure control, fewer pieces of equipment to maintain, and a much leaner energy profile – a win-win for both productivity and sustainability.
SMARTCair
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