Operational Costs Soar as Inefficient Air Compressor Systems Rob the Bottom Line

Waste not, want not. No truer axiom applies when it comes to eking out maximum efficiency from processing, manufacturing and service facilities. Yet, every day witnesses wasted opportunities to reduce expenses, simply because of inefficient electrical equipment. The losses can quickly eat into profits, as pointed out by the Motor Decisions Matter™ campaign by the Boston-based Consortium for Energy Efficiency when it found that: Motor energy costs can exceed $1 million annually in large industrial plants. On the other hand, the consortium also noted that: According to the U.S. Department of Energy, greater attention to motor system management can reduce these costs by 18%. For this reason, many commercial and industrial plant managers are turning to direct-drive air compressor systems.

In the case of air compressors, the efficiency benefits of this new direct-drive technology stems from two important design improvements. First of all, a direct-drive rotary screw eliminates unnecessary moving parts such as belts, gears and pulleys—thus reducing the parasitic losses attributed to belts (4-8% loss) and gears (3-5%) respectively. Secondly, such compressors employ larger rotors in the air-end assemblies that, in effect, offer a "higher displacement" so that they turn slower while producing an equivalent amount of cubic feet per minute of air.

"Stated quite simply: you get more air, at higher pressure, using less horsepower, with the newer direct-drive compressors," says Steve Van Loan, President of Sullivan-Palatek—a Michigan City, Indiana, manufacturer of industrial equipment. "Most electric air compressors, particularly in the 5-100 horsepower range, are belt or gear driven. However, by omitting unneeded gears and pulleys you can reduce driveline friction and avoid wasting anywhere from 3-8% of your operating efficiency for that piece of equipment. Why let those dollars slip through your fingers?"

This wasted efficiency can be put into perspective by comparing a chain or belt-driven air compressor that requires 112 hp to supply a given air flow rate at a given pressure, vs. a direct-drive unit that only requires 100 hp to produce the same amount. At an industry-standard average of $.08 cents per kWh, the need for an extra12 hp would unnecessarily increase electricity costs by approximately $4200 per year.

"We use compressed air to remove motor parts, wheels and tires," says Jim Cook, Construction Manager of California-based Pick Your Part, the nation’s leading self-service auto wrecker. "But we were frequently running out of air with our piston air compressors. However, we now use 25- and 30-hp direct-drive units from Sullivan-Palatek. The additional horsepower we get from each new air compressor gives us added efficiency and economy.”

By averting losses from inefficient equipment, businesses stand to save significant amounts of money that can be put to better use such as plant expansion, R&D, or simply fattening the bottom line. As pointed out in a U.S. Dept. of Energy-sponsored report by National Renewable Energy Laboratory: using new technologies increases energy efficiency…improves profits.

Established in 1984, Sullivan-Palatek manufactures industrial equipment such as electric and diesel driven high performance rotary screw air compressor systems, with a complete line of accessory items that include air dryers, filters, remediation systems and construction air tools.

For more information:

Sullivan-Palatek
Steve Van Loan
svanloan@palatek.com
3501 W. Dunes Highway
Michigan City, IN 46360
Phone (219) 874-2497
Toll-free (800) 438-6203
Fax (219) 872-5043
Email: info@palatek.com
Web site: www.palatek.com