Variable-speed compressors are worthy investment

Dunlop Equipmen turned to CompAir when a fire at its factory disrupted some of its compressed air equipment earlier this year.

Dunlop Equipment, a leading UK supplier of aero-engine subsystems and accessories, turned to CompAir when a fire at its factory disrupted some of its compressed air equipment earlier this year.

CompAir, a global manufacturer of compressed air and gas systems, teamed up with its distributor, Oscott Air, to install two fixed-speed L45 compressors and one L45SR variable-speed compressor from its super efficient L Series, just eight days after the fire severely damaged the compressed air room at Dunlop Equipment's Coventry site.

Dunlop Equipment has a long-established reputation for world-class engineering.

Its pneumatics and fluid control solutions are used in a variety of aerospace, marine and general industrial applications such as large jets and helicopters and gas turbines for power generation.

In these extreme environments, reliability and performance are key and Dunlop Equipment uses state-of-the-art design tools to minimise design to production cycle times and ensure its products remain at the cutting edge of technology.

It is crucial that Dunlop Equipment's compressed air equipment is equally high-performing.

Compressed air is used for the manufacture and testing of products such as engine components and air/oil separators.

Prior to the incident, Dunlop Equipment had already decided to upgrade two of its four existing compressors to a single L45SR variable speed compressor from CompAir.

A data-logging exercise, which calculates wastage in compressed air usage, highlighted the energy and cost savings that could be made.

Like many businesses, Dunlop Equipment realised that by using compressed air more efficiently and recognising the peaks and troughs in its demand, it could make significant savings and reduce the number of compressors in its system while maintaining high quality and superb performance.

When four of Dunlop Equipment's compressors were damaged in a fire it was crucial that they were replaced as quickly as possible in order to resume production.

Roy Cheevers, Site Services Manager for Dunlop Equipment, approached CompAir distributor, Oscott Air, which offered to replace his machines within record time.

Cheevers recalled: "We had already looked into the feasibility of replacing two of our fixed-speed compressors with a variable speed model as we knew that we could increase efficiency and cut costs as a result".

"We were interested in a CompAir machine, as we knew that the quality of its machines could stand up to our demands, and had approached Oscott Air a few weeks previously so they could make recommendations for our system".

"The fire meant we had to make a move much more quickly than originally planned but making the right choice was still key and we didn't want to rush our decision".

"Although CompAir offered to replace our machines within days we made sure we obtained further quotes from other manufacturers and used a mobile compressor in the meantime to ensure that service levels were not jeopardised".

"It turned out that not only was CompAir our original choice but they were the most competitively priced and could offer the fastest turnaround on our order".

"This was a relief as the mobile compressor was draining gallons of fuel a day and had cost us significantly in the two weeks following the incident".

Andrew Power, Business Development Manager at Oscott Air, commented: "Many businesses are still unaware of how much energy their compressed air systems are using and therefore how much energy could be saved with a variable-speed system".

"Dunlop Equipment had four fixed-speed compressors which were wasting energy as not all of the air produced was being used".

"We recommended a speed-regulated compressor which is much more efficient as it supplies air when and where demand dictates, keeping energy usage to a minimum".

The CompAir L45 and L45SR are part of the L Series of oil-injected rotary screw compressors.

The range is based on a flexible modular design so customised features, such as larger air-ends or integrated dryers, can be added.

The compressors also boast small installation footprints, lifting slots and vertical air discharges which simplify installation.

The L45SR incorporates a variable-speed switched reluctance drive system of outstanding efficiency; offering the ability to precisely match power consumption with air demand.

Where conventional motor drive systems require a high starting current, the L45SR is able to start without any increase in power supply above normal running levels, reducing stress on the site's power supply and eliminating peak current energy cost penalties.

To integrate the three machines, Dunlop Equipment also had a CompAir controller fitted which works with the compressors to control and regulate the flow of air so that none is wasted.

Cheevers continued: "Our insurers were surprised that we had replaced four compressors with just three but I explained that as technology advances equipment becomes more and more efficient, and we already have proven results - our CompAir controller shows that potentially, we could make an incredible 56% saving on energy".

"I'm actually looking forward to seeing our first electricity bills and I'm confident that it won't be long before the new compressors have paid for themselves".

Colin Mander, Director Industrial Sales at CompAir, commented: "The energy savings Dunlop Equipment has already seen reinforce the efficiency and many other benefits of our rotary screw compressors".

"The compressors are clearly paying back the investment that the company has made and, most importantly since the fire, are ensuring the business can operate without the fear of breakdown".

"As the compressors also come with a 24,000 hour Assure warranty, Dunlop Equipment has the reassurance that its maintenance costs will be significantly reduced".

"It is clear that the new compressors, in particular the variable speed L45SR, will prove to be a worthy investment for Dunlop Equipment and any other companies looking to make energy savings".

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