How Air Compressors Contribute to Sustainable Manufacturing

In an interview with Industry Outlook, BK Jha, MD, Fibre Equipment talks about how the technology of air compressors is revolutionizing the manufacturing industry. He points out the trend towards energy-efficient technologies, enhanced operational reliability, and the implementation of smart maintenance systems. He also highlights the importance of screw air compressors in minimizing power consumption and downtime, while helping to achieve sustainability objectives.

How are you providing optimizing air compressor systems to reduce power consumption and align with sustainability goals?

The screw air compressor is being implemented to save energy. We compare it to a reciprocating air compressor. A reciprocating air compressor is a positive displacement machine, and a screw air compressor is also a positive displacement machine. Yet, there are quite several differences between a reciprocating air compressor and a screw air compressor. A reciprocating air compressor functions similarly to a petrol engine. It consists of three components: the first component for suction, the second component for compression, and the third one for discharge. Hence, it requires more time and energy.

But, in a screw air compressor, there isn't any specific cycle of suction, compression, and discharge. Its rotor, constructed similarly to a helical gear, displaces the air out of reach from both rotors and blows the air out directly. So, it's more efficient and uses less power than a reciprocating air compressor.

What strategies are service providers using to improve air compressor reliability and prevent unplanned downtime in manufacturing?

The screw air compressor has its own controller, an electronic microprocessor-based controller. This controller monitors and analyzes all the operating parameters. It reads variables like changes in temperature, pressure levels, inlet and outlet pressure of oil, and water. It is not a water-cooled system but air-cooled equipment. It monitors the air pressure and the outgoing air pressure. All these parameters are operated by the controller, which is microprocessor-based.

In this controller, the programming logic is already set to determine how much temperature the system should reach and how long the compressor should run. All such counters and parameters are saved in the microprocessor-based controller. This makes it extremely simple to keep track of how long the machine is loaded and how long it is unloaded. This functionality allows for easy planning of maintenance services. If any parameter goes into warning and the compressor begins to overheat, we can instantly see what is going on with the compressor.

Another key feature of this controller is the ability to track past breakdowns. It retains information on the last ten breakdowns, whether they were caused by temperature problems, voltage problems, or any other fault that led to the machine shutting down. These messages are stored, so it is simple to know what previously occurred with the compressor. From this controller, we can easily identify what happened with the machine, observe the data, and solve the problem. All things are based on this microprocessor-based controller, which makes compressor operation very easy.

How are advanced monitoring and predictive maintenance solutions transforming the manufacturer's managed air compressors to significantly cost efficient?

About 70 to 100 years ago, there was only one machine available to compress air. In the year 1965, the first screw air compressor was launched in Belgium. In India, the first screw air compressor was launched around 1989, which was also from Belgium. Thus, the application of screw air compressors was initiated in India in 1989.

Then all the industries were employing reciprocating air compressors. The equipment consumed more energy and less efficiency. Metal-to-metal contact was there in such compressors. The configuration was a cylinder and piston type where air was compressed by cylinder and piston rings. The system produced high temperatures and created more issues and downtime due to this metal-to-metal contact. In such a situation, the screw compressor emerged as the optimal choice in comparison to the reciprocating air compressor.

How are service providers helping manufacturers compare with evolving efficiency standards for compressed air compressors?

In this modern era, we have advanced machines that can produce more efficient screw rotor cutting profiles. Such equipment helps create screw rotors that require less power to run while providing greater efficiency and capacity. We have brought these innovations to the entire product range, including the N-series. This is one of our manufacturing innovations—the N-series screw air compressors. The N-series has an improved metalized rotor, which contributes to improved performance.

How are service providers integrating waste heat recovery from air compressors to enhance overall plant efficiency and support nuclear manufacturing initiatives?

Heat recovery is extremely crucial for any sector. In our product, we have included all the necessary coolers required to recover heat. Firstly, we have already mentioned a low RPM screw air compressor. When the screw component runs at a lower RPM, it automatically produces less heat. Consequently, the temperature does not increase much. Secondly, we have installed the use of a combi cooler. A combi cooler works like a radiator. In this system, the compressor blows air through the combi cooler. The combi cooler then cools the air before it continues to the main utility.

What emerging technologies such as AI, variable speed drive, alternative compression and sustainable air compressor systems?

Artificial Intelligence (AI) has only now been implemented in this sector. As of now, within our industry, AI is not applied. But this industry certainly requires the inclusion of AI. To clarify, take an example when a machine is in operation and suddenly breaks down. In this situation, the customer initially calls our service engineer. The engineer then goes to the location, examines what went wrong, explores the past issues, and checks the history of breakdowns.

If we incorporate AI into the system, we can keep monitoring the machine in real-time through our screen. By integrating the controller with AI, we can see what is occurring on the customer's side without the need to send an engineer straight away. We can identify problems beforehand and act accordingly. That makes the process faster and more efficient. All manufacturers of compressors today are in the process of designing more modern, efficient air compressors. Everyone is thinking in terms of producing machines that operate at lower RPM but yield more capacity. We are all working day and night to implement this.

How can air compressor maintenance practices contribute to a more sustainable manufacturing process by extending equipment lifespan and reducing waste?

Maintenance is an extremely significant part of any machine—not only for compressors but for machines in general in all industries. We have a controller which is microprocessor-based that constantly monitors significant parameters. It keeps track of how many running cycles the machine is experiencing, how many running hours it has done, and in the course of those hours, how many times the machine has experienced being in the loaded or unloaded position. This makes it very simple to schedule and plan for maintenance operations well. If an industry follows such a structured approach to monitoring and planning, it becomes easier to ensure the compressor operates efficiently over a longer period.

What role do compress air systems play in reducing this carbon footprint of manufacturing operations and how can this be managed effectively?

Decreasing power usage by effective air compressors directly contributes to reducing the carbon footprint. That's why we always advise our customers to avoid fixed-speed machines and instead use Variable Frequency Drive (VFD) compressors. The VFD system modulates power usage according to actual demand, synchronizing electricity usage with needed capacity.

The majority of customers are not aware of the precise air capacity required in their plant. For instance, if their need is merely 30 HP but they put in a 50 HP compressor, the additional 20 HP leads to wastage of energy. This results in wastage of electricity and increased cost of operation. We highly recommend our customers to select VFD-based compressors. It is the most optimum solution for reducing energy use and environmental footprint through smaller carbon footprints.

What are the economic benefits from manufacturing adopting more customary air compressor technology and long-term environmental benefits?

When you utilize a power-efficient compressor, your energy usage goes down. And when energy usage goes down, it becomes advantageous—not only for the user but for any industry in general. When we produce our screw air compressors, we build them with long-term performance in mind. Through the use of high-quality components and sophisticated metalizing processes, we can greatly extend the life of the machine. But even the life-giving speed of the compressor can be dependent upon the user. Regular maintenance is crucial to the overall life and operation of any machine. We emphasize quality intensely. With improved profiling and accuracy machining, we provide compressors that are long-lasting in nature—lasting up to 15 to 20 years.