Containerised Low Pressure Compressor System

25th February

Client Overview🏭

A leading UK cement manufacturer approached Aircare Compressor Services to support an upgrade to their low-pressure compressed air system at one of their production sites. The project formed part of a wider plant improvement programme aimed at increasing efficiency, reliability, and long-term maintainability of critical equipment.

As specialists in compressed air engineering and system optimisation, Aircare was selected to design and deliver a practical, cost-effective solution that could be installed safely within an operational cement plant environment.

The Challenge

The customer needed a purpose-built enclosure to house new low-pressure screw compressor packages installed near an existing cement mill. The key requirements were:

• Provide weatherproof, secure housing for new compressor equipment

• Ensure adequate airflow and ventilation to maintain safe operating temperatures

• Allow full maintenance access without requiring equipment removal

• Integrate safely within an existing plant layout with minimal disruption

The installation area was restricted, and the solution had to be positioned close to existing blowers while maintaining safe working access and airflow management.

The Aircare Solution✅

Following site surveys and technical discussions with the client’s engineering team, Aircare designed and supplied a fully customised compressor housing package.

Key elements of the solution included:

1. Custom 20ft Side-Access Container
A new full side-opening 20ft container was supplied and re-engineered at Aircare’s Corby facility to house the compressor packages. The design included end access doors and full-length side access panels to provide easy maintenance access and safe working conditions for engineers.

2. Mechanical Engineering & Pipework Fabrication
Stainless steel pipework was fabricated and installed within the container prior to delivery. Pipework terminated with flanged connections ready for final onsite integration into the cement mill system, reducing installation time and risk on site.

3. Electrical Preparation
Internal lighting, 110v sockets, and cable containment were installed to support safe operation and maintenance activities, ensuring safe working conditions for engineers carrying out inspections and servicing.

4. Ventilation & Airflow Management
To maintain safe compressor operating temperatures, the container was fitted with a forced ventilation system, including inlet louvres with removable filters and a high-capacity extraction fan to provide sufficient airflow.

5. Delivery & Installation
The fully engineered container was transported to site using a specialist heavy plant moving contractor and positioned in the agreed location using HIAB lifting equipment, helping minimise disruption within a live production environment.

Project Outcome

The completed installation delivered a robust, fit-for-purpose housing solution for the new compressor packages. By completing fabrication work offsite, Aircare reduced installation time and helped keep plant downtime to a minimum.

The client now benefits from:

• Durable, weatherproof compressor housing

• Improved maintenance accessibility

• Correct ventilation and temperature control

• Safe and compliant installation

• Reduced installation risk through offsite engineering

Customer Testimonial✨

” Many thanks for the professional and well managed delivery lift of the container and the blowers, very professionally performed and managed from Aircare team involved and the H&S standard was maintained to an excellent level. Thanks again.”

Looking Ahead📈

We continue to support customers across manufacturing, food production, automotive, and heavy industry with engineered compressed air solutions, maintenance support, and system optimisation projects.

If you’re planning upgrades, relocating compressors, or looking to improve efficiency and reliability, our team would be happy to help.