September 2020

COMPRESSED AIR www.hpmag.co.uk enter the system, downstream air dryers and double line filters are used to further purify the air. But filtration itself raises two more problems. First, given that approximately 10 million litres of oil have been expelled into the atmosphere over the past ten years from oil-lubricated compressors, the safe and sustainable disposal and re-use of oil continues to be a challenge. Secondly, filters create a drag on efficiency by their very function, resulting in increased energy use and running counter to the very goals of operations leaders in the food and beverage sector. For every filter that is installed in the downstream compressor line, you increase the differential pressure. This results in an increase of energy consumption of approx. 1% per filter. Furthermore, filters are often installed and paired in various combinations in the compressor room and at the point of use, resulting in additional cost and efficiency loss. Thus, meeting these requirements for contaminant-free air in the food and beverage sector has always seemed at odds with the need to reduce the total life cycle cost. Best of both worlds Today, innovation and new product development has resulted in solutions that deliver ISO:8573 (P2):2007 ‘Class 0’ oil-free air to ensure that 100% contaminant-free air is produced for various applications in their manufacturing and packaging processes. Until recently, these compressors were expensive and used primarily by large companies and those that exported their 42 HYDRAULICS & PNEUMATICS September 2 020 products to markets with stringent standards (for example as set by the EU’s European Food Safety Authority). Now, technology advancement and market developments in oil-free technology and ‘Class 0’ certified compressors have changed the game and every manufacturing company can access technology that assures not only oil-free air that meets the most stringent standards, but also much higher energy savings and uptime at lower life cycle costs. For example, there are very few compressor companies that design their own oil-free air-ends and even less that make them along with their own pressure vessels, castings, motors while also conducting complete machining and compressor assembly. With in-house technology and manufacturing capabilities of all these various elements, compressors can now be engineered to deliver maximum uptime and reliability, leading to an optimised compressed air system for operators. Designing compressed air for the operational situation = lower life cycle cost + contaminant-free compressed air The technology exists to affordably cater to the dual demands of contaminant-free air and improved life cycle cost. But we can and should do more. As my example at the beginning of this article highlights, Food and beverage operational leaders need not only the best and most reliable compressors, but also expert support in designing and optimising the complete compressed air system – a trusted partner that will understand and tailor their needs to further improve their twin goals. Plant leaders should consider a ‘bird’s eye view’ of the compressed air system – understanding the supply and demand sides, and starting in the point of generation, through transmission and finishing, where the air is used at the end of the line. A solution-focused, comprehensive approach building on the components but holistically looking beyond just the compressor room is essential to lowering the life cycle cost. Cheers to our food and beverage sector The food and beverage sector must contend with increasingly demanding regulatory challenges regarding quality, safety and energy efficiency while addressing the need to feed a growing population sustainably. Given that compressed air is often referred to as the ‘fifth utility’ in acknowledgement of its vital role in manufacturing, the compressed air industry must continually innovate so as to support food and beverage operations in meeting these challenges. With the advance of energy efficient oil-free compressed air, this technology is set to grow in relevance not just for the food and beverage industry but for all applications. Oil-free air will become more prevalent supported by design initiatives to further improve cost and efficiency, data will serve as a key enabler and with this the evolution of change will speed up delivering ever increasing savings and improvements for this vital energy source in manufacturing. www.elgi.com/eu