9th January 2015
CompAir compressors furnish Bluespot Furniture with 30 per
cent energy savings
Bluespot Furniture Limited (Bluespot) is saving over 30 per cent in energy
costs, thanks to a new compressed air system from Gardner Denver
(CompAir) distributor, Advanced Compressor Engineering Ltd (ACE Group).
Around 12 months ago the company, which manufacturers an extensive
range of commercial and residential furniture systems, installed two CompAir
L37 fixed-speed compressors and one L37RS speed-regulated unit as part of
a site move to a new purpose-built facility. This has cut the number of
compressors from six fragmented units to an integrated package of three, with
reduced the air pressure from 10 bar to 7 bar, a saving of 21 per cent.
Bluespot was established in 2001 and grew progressively as a result of
increased product offerings in contract office furniture and student
accommodation installations, resulting in operations spread across four
separate units. This meant that the compressed air system had become
fragmented, with air line systems added over time to accommodate the
increase in demand as production grew.
In mid 2013, the company took the decision to purchase a modern production
unit nearby and consolidate its four units in to one facility. This gave Bluespot
the opportunity to carefully plan the layout of the production process and, an
important element of this was the design of the compressed air system as Dr.
Andrew Cooper, Operations Director explains,
Continues…
“Compressed air is a key component in the efficient operation of our
production process. It is used extensively across the factory, providing
processing air for each stage in manufacture including panel cutting, edging
and drilling.
“Although our existing compressed air supply provided the volumes and
quality of air that our process required, it had been added to over time and
was therefore not delivering the high levels of efficiency we required. Our
machinery requires a constant supply of air at 6.5 bar but, at the old site, to
compensate for air losses in the pipework and general system inefficiencies,
we had upgraded the compressors to operate at 10 bar.
“In addition, we wanted the new facility to maximise productivity at every
stage of the process. Our existing compressors were sited at the point of use,
meaning our operatives had to wear mandatory hearing protection –
something we were keen to overcome to help improve the working
environment too.
“Working closely with ACE Group, we were able to specify a brand new air
system. This comprised a new compressor house located outside of the main
production area, sized to suit our current air requirements but able to meet
additional demand as part of our plans for business development for the
future. ACE installed new aluminium, full bore pipework which is both
lightweight and highly efficient, helping to reduce pressure losses
significantly.”
Andy Crone, Group Sales Director from ACE Group explains how the new
system has been optimised to save energy:
“The previous system was energy-intensive as the compressors were running
continuously rather than adapting to changes in production demand.
Continues…
“As a result, we advised Bluespot against moving their existing compressors
across to the new facility but instead, recommended a combination of fixed
and speed regulated units to meet peaks and troughs in air demand.
“We loaned the company a compressor during the early stages of the move,
which we monitored over a period of time to access site air demand and to
help identify where savings could be realised. Data logging of air usage was
conducted by ACE specialists to monitor the air usage in the new factory prior
to final confirmation of new compressor specifications.
“The resulting installation comprises two CompAir L37 fixed speed
compressors, which are rotated to provide the base load and the speedregulated L37RS which comes online to meet peaks in demand. These are
controlled by the CompAir SmartAir Master compressed air management
system, to help even out compressor running hours and continually provide
the most cost-efficient means of generating air.
“A high-efficiency refrigerant dryer, with pre and post filters provides clean, dry
air throughout the network.
“A single air receiver tank was also specified in place of a number of tanks at
the previous facilities, helping to reduce maintenance requirements
significantly.”
Andrew Cooper concludes, “It is important for any manufacturer to be able to
focus on its core skills of producing a high-quality, finished product and work
with suppliers that can provide other technical expertise. We were able to rely
on ACE Group to not only commission a quality compressed air system, but
also provide ongoing service and maintenance.
Our new compressor system has exceeded our expectations in terms of
energy efficiency and one year on, we are realising savings in excess of 30
per cent.”
-Ends-
For further press information please contact:
Grant Bostock or Jane Woods
01785 255146
Edson Evers Public Relations
120 Newport Road
Stafford, ST16 1BY
grant.bostock@edsonevers.com
jane.woods@edsonevers.com