CUSTOMER
Wicklow based packaging manufacturer requiring
full turnkey
solutions for their compressed air
The solution
systems, preventative maintenance sales and
ILS Engineering
Service
servicing
for its state of
the art Manager,
facility in Paul
County
Kelly,
takes
up
the
story.
“Rather
than
Wicklow, Ireland.
specifying an oil-free compressor, which
PROJECT
many see as the only way to go, we
Offer consultancy, supply and install an oil-
worked back from the air quality required.
flooded compressor, integrated equipment and oil
We found we could achieve it at a fraction
converter to upgrade the existing air system.
of the price and allow the customer to
BOGE
PRODUCTS
IN USE equipment, by
keep
their oil-flooded
• BC including
oil converter
a BOGE BC oil convertor in the
• 90 set-up.
kW SLF This
125 unit
oil-flooded
screw
compressor
effectively
converts
oil
• DS180
refrigerant
drier
hydrocarbons from the air into carbon
• Duotherm
exchanger
dioxide and
water.”
• Airstatus external monitoring system
PROJECT INFORMATION
The new oil-flooded screw compressor
is a BOGE SLF 125 model. Its energy- THE CHALLENGE
saving features include direct connection With an expansion in production,
between the air end and motor. It also
has variable speed control, which enables
• Lower downtime and higher
optimal adjustment to meet changing productivity – with increase in
needs and avoid working unnecessarily compressor power from 55 to 90 kW
Oil-free compressed air – without
oil-free compressors
hard. Its free air delivery of 554 CFM is a
substantial increase over its predecessor.
A BOGE DS180 refrigerant drier, complete
with filtration, extracts water and other
Are oil-free compressors the only way to
contaminants from the air. A BOGE
guarantee oil-free compressed air? With
Duotherm recovers heat from oil and
help from BOGE Compressors and their
transfers it into the building’s hot water
distributor for Ireland, ILS Engineering,
system. BOGE’s Airstatus external
one packaging manufacturer has found
visualisation and monitoring system,
an alternative
requiring substantially less
connected through a portal to the BOGE
investment – and has made impressive
data centre, provides vital information,
efficiency
savings as well.
analysis and alerts via mobile app or
is no ongoing
subscription
When desktop.
planning There
to upscale
the machinery
cost for
this management
tool.
at its plant
in Wicklow,
Ireland, switching
Installation
took just
two days
to oil-free
compressors
seemed
the and
only was
break
option completed
that would during
satisfy the
ILS Christmas
Engineering
with
no
interruption
to
production.
customers’ air quality demands. Instead, The
old duty
the existing
air compressor
system has has
now been
been retained as
a
standby,
while
the
old
standby
upgraded by adding a new oil-flooded will also
be available
use.
compressor,
along for
with
integrated
equipment including a BOGE BC oil
Results in brief
converter.
• High-quality air – oil concentration
Independent
testing shows a reduction in
0.0006 mg/m3 – well within required
airborne limit
oil concentration
to 0.0006 mg/
of 0.009 mg/m3
3
m . This is much cleaner than the industry-
• Improved air efficiency – estimated
annual saving of €13,000 to €14,000
• Lower purchase cost – estimated
saving of €500,000 across all sites,
compared to switching to oil-free
compressors
specified limit of 0.009 mg/m 3 and is far
better than the
test results achieved by
Customer
satisfaction
many systems with oil-free compressors.
The
decision
go ahead compressed
The ultimate
new set-up
also to
generates
was
made efficiently
by the Plant
air more
and Director,
reduces who
energy
enthused:
“We
considered
the BOGE
and
bills further
through
effective
heat recovery.
ILS solution carefully and it ticked every
saving of €30,000 on water heating
bills thanks to heat recovery
manufacturer needed to upscale
its compressed air supply to
ensure its plastic packaging
PROJECT INFORMATION
wasn’t contaminated during the
production
Compressed
THE process.
CHALLENGE
With an in
expansion
in production,
the Wicklow
air is essential
powering
the
based
packaging manufacturer
company’s
operations
and the needed to upscale
its compressed air supply to ensure its plastic
packaging wasn’t contaminated during the
having to production
rely more
and more
process.
Compressed air is essential
on the standby
compressor.
The
in powering the company’s
operations and the
packaging
firm was
finding it was having to rely
system was
no longer
meeting
more on the standby compressor. The
demand, more
with and
downtime
a real
system was no longer meeting demand, with
issue, and switching to oil-free
downtime a real issue, and switching to oil-free
compressors
would would
require
major
compressors
require
major investment.
packaging firm was finding it was
Packaging
box.
When we perfection
saw the independent test investment.
This manufacturer,
has surprised
been producing
results,
we were all very
and THE BOGE
SOLUTION
Rather
than making a snap decision to replace the
for over 80 by years,
a wide ” range of
impressed
what offering
it could achieve.
standard and bespoke packaging designs.
He
“They
have
simply
sold
To adds:
maintain
the could
quality
and
safety
of the
us
oil-free compressors,
packaged
products they which
must would
be free from
have
made more money for them, but
contamination.
THE BOGE SOLUTION
system with oil-free compressors, ILS Engineering
Rather than
making a snap
they chose to find a solution that worked offered consultancy and came up with a
better and cheaper option for their customer.
with oil-free
compressors,
ILS a Boge BC oil
An integrated
system including
Engineering
offered
consultancy
converter,
a new
oil-flooded screw compressor
Duotherm
heat recovery
and came and
up a with
a better
and system.
better
for us. I air
think
this says a to lot
about the
Compressed
is essential
powering cheaper option for their customer.
how
important
long-term
company’s
operation
and customer
is fed into almost An integrated system including a
all equipment are used
for manufacturing
relationships
to them.
”
plastics. This includes everything from the
He
concludes:
“Many machine
companies
in this
injection
moulding
to raw
material
market
are and
being
told systems,
they need
oil-free
transport
feed
valves
and
compressors,
but we’ve
product assembly
lines. shown that this
decision to replace the system
THE RESULT
Annual energy savings of €44,000, a saving
Boge BC of oil €500,000
converter,
a new
compared
to oil-
switching to oil-free
compressors,
better air and
quality
flooded screw
compressor
a to well below
the heat
industry
specified system.
limit, greater productivity
Duotherm
recovery
from increased power and no downtime during
THE RESULT
installation.
isn’t always true. If customers tell us their Annual energy savings of €44,000,
air requirements, we’ll explore the options a saving of €500,000 compared to
and give them the best solution at the switching to oil-free compressors,
on energy
input
Project
report: Bottle Cap Manufacturer best price.”
• Lower heating bills – estimated annual
the Wicklow based packaging
www.boge.com
better air For
quality
to information
well below the
more
see www.boge.com
industry specified limit, greater
productivity from increased power
and no downtime during installation.
FDPP - www.fdpp.co.uk 11