Tag: efficiciency

Variable Speed Drive Air Compressors

Published on by John BallLeave a comment

Compressed air is a clean utility that is used in many different ways, and it is much safer than electrical or hydraulic systems.  But most people think that compressed air is free, and it is most certainly not.  Because of the expense, compressed air is considered to be a fourth utility in manufacturing plants.  I did write a blog earlier titled, “Basics of Compressors”.  There are two main types of speeds for air compressors; fixed and variable.  In this blog, I will cover the Variable Speed Drive (VSD) Air Compressors. 

The VSD Air Compressor controls the speed of the electrical motor by supplying different frequencies and voltages.  It can range from around 20% capacity to 100% capacity depending on the system requirement.  With most systems, the amount of air flow fluctuates throughout the day.  With a VSD Air Compressor, it can run at lesser horsepower ratings for lower demands.  If your plant operates at different compressed air demand levels, the VSD air compressor can help cut the electrical cost. 

 As an example, let’s say you have a 20-horsepower air compressor which can produce roughly 100 SCFM of compressed air.  If the demand drops to 20 SCFM, then the VSD can change the ratio of the electric motor to run like a 4-horsepower compressor.  And a 4-horsepower compressor uses much less electricity to generate compressed air. 

Overall, the VSD does offer better efficiency if there are fluctuations on the demand side.  To go even further, EXAIR has been manufacturing Intelligent Compressed Air Products since 1983.  We are able to save you money by reducing the use of compressed air on the demand side.  Together with a VSD air compressor, our products will help a compressor system to operate at much lower electrical power, saving you money.  If you need alternative ways to use your compressed air, an Application Engineer at EXAIR will be happy to help you. 

John Ball
Application Engineer
Email: johnball@exair.com
Twitter: @EXAIR_jb

Photo: Technical Illustration of a portable single-stage air compressor by Brain S. Elliot.  Creative Commons CC BY-SA 4.0

Methods, Patterns, and Continuous Improvement

Published on by Brian FarnoLeave a comment

I’ve blogged about the fact that I am married to an amazing woman and we have been blessed with three incredible daughters before. My wife and I are constantly being reminded of just how different raising kids in this digital and rapidly changing world is compared to when we were kids. And, just writing those statements makes me realize I have truly entered the next (I’m old) chapter of my life.

My oldest, who is 12, is at that point where she is gaining some independence at middle school, and at the same time is getting sucked into social norms where she can easily be consumed by social media and screen time. The challenge I took on was to find something analog that we could both pick up and enjoy, maybe even challenge each other with. Enter a classic that I was never able to master, and still can’t without the aid of another (my 12 year old), the Rubik’s Cube. I was honestly shocked when she took the time to review a video from our library and learned the patterns to solve the cube. Turns out a few of her friends are even able to solve them and thus the education began.

A traditional 3×3 Speed Cube in a solved state then converted to a checkerboard pattern.

What I once thought was an impossible task was broken down into patterns and a logical path to correct and straighten out the tangled squares. The are a number of methods to solve the standard 3×3 cube. No matter what, the pattern has to be recognized, implement the steps to solve, and then improve through repetition. Not many people pick something like this up, solve it once and then sit it down. It becomes a process of continuous improvement and that is exactly what my daughter took on. For me, it reminded me of Lean Manufacturing and every process I have ever looked at professionally. It was truly rejuvenating for me to see her take on the challenge and then have an urge to improve her process time.

When I came into work the next day, it clicked. That same process of methodical movements could all connect to our Six Steps to Compressed Air Optimization. Each of these steps is solving another layer of a mixed up cube. While at first, the process of optimizing a compressed air system can easily seem out of reach it is easily broken down into steps that result in a solution. Then, instead of taking all of that new found knowledge to only conduct the six steps once, you can easily make this a recurring event. Because even though your facility may not change, the air system will, new leaks may appear, items on the supply side may wear, demand side application may change as processes are added or modified.

Processes lead to continuous improvement.

Continuous improvement is a method that propels a system forward toward efficiency and improved outcomes and it is something that is needed to stay relevant. Even with the methods of solving a 3×3 cube, those methods continue to evolve and the main level of improvement is often on the person spending time with the process. If you want to discuss a compressed air application in your facility that could stand some improving or maybe you want to share your solve times on the 3×3 cube, don’t hesitate to reach out to me.

Brian Farno
Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF