Compressed Air Upgrade for Top Convenience Food Provider

Client: A leading convenience food producer
Industry: Food Production
Challenge: Upgrade a compressed air system with a focus on efficiency and reliability while minimizing downtime

The Challenge

A long-standing client, a large-scale producer of convenience food, approached Aircare Compressor Services with a critical project: to upgrade their aging compressed air system. Their existing system, a CompAir L250, was struggling to meet the demands of their operations efficiently, and reliability concerns were growing. The client needed a solution that delivered improved efficiency and operational reliability without disrupting their production processes.

The Solution

Aircare’s Sales Director, Steve Flint, began the project by deploying airINSITE, a comprehensive data logging system, to analyze the client’s existing setup. This diagnostic step was crucial in understanding system usage patterns, inefficiencies, and overall performance.

The data revealed that a CompAir L110FC RS Four Core was the ideal replacement for the L250. This model offered:

• Two-stage efficiency in a single-stage footprint for space savings.
• Up to 8% improved energy efficiency compared to other models.
• An estimated annual saving of £13,372.22 on energy costs.

The CompAir L110 was the perfect choice for boosting efficiency and maintaining reliability without expanding the system’s footprint—a critical consideration for the client.

Execution

Once the client approved the proposed solution, Aircare’s expert service team stepped into action. The project included:

1. Decommissioning the L250: The team disassembled and stripped down the existing compressor into manageable parts. This step was carefully planned to ensure smooth removal and transport to the roof space.
2. Minimizing Disruption: Work was scheduled over the weekend to avoid downtime and ensure the client’s operations remained unaffected.
3. Installing the L110FC RS: The new compressor was lifted in through the roof and maneuvered into its designated space within the compressor house.

The new system was connected using PREVOST smoothbore aluminium pipework, ensuring an efficient, high-performance setup with minimal pressure drops.

The Results

With the upgraded system in place, the client is now benefiting from:

• Significant cost savings: estimated to be £13,372.22 in annual energy savings.
• Enhanced efficiency: Improved operational performance with reduced energy usage.
• Reliability: A robust system with the latest technology, that minimizes the risk of downtime, keeping production on schedule and giving the client peace of mind.
• Optimized space utilization: The compact footprint of the L110 maximized efficiency within the available floor space.

Conclusion

This project highlights Aircare’s expertise in tailoring compressed air solutions to meet clients’ unique needs. By combining data-driven insights, cutting-edge equipment, and expert installation, Aircare delivered a solution that enhanced efficiency, reliability, and cost savings for the client.

Ready to optimize your compressed air system? Contact us today.