Energy Efficient Compressed Air Upgrade

A recent Avelair installation has shown how an energy efficient compressed air upgrade can transform both energy performance and air quality standards within a busy engineering and fabrication environment. The client required a reliable and efficient compressed air solution that could support continuous production while meeting strict breathing air requirements for operator safety. Their existing fixed speed compressor had become increasingly inefficient and costly to run, which prompted the decision to upgrade to a more advanced and economical system.

Replacing inefficiency with Smart Variable Speed Technology

The previous fixed speed compressor operated regardless of demand. This resulted in excessive energy consumption, higher running costs and unnecessary wear on the system. After completing a full site assessment and reviewing the air usage profile, Avelair recommended the installation of the Avelair VSDR 22 which is a highly efficient variable speed direct drive compressor designed to match output precisely to real time demand.

By automatically adjusting its motor speed to suit actual usage, the Avelair Variable Speed Drive air compressor eliminates the constant load and unload cycling that is common with traditional fixed speed units. This significantly reduces electricity consumption and lowers system stress which results in a quieter, cooler running and far more economical compressed air supply. For businesses with fluctuating demand the energy savings delivered by variable speed technology can be substantial.

Enhanced Air Quality with Advanced Drying and Filtration

In addition to improved efficiency the client required exceptionally clean compressed air suitable for breathing air applications. To achieve this the new installation included a high efficiency refrigerant dryer a robust three stage filtration system and dedicated point of use breathing air filtration that meets the requirements of BS EN 12021.

This multilayered approach ensures the removal of moisture oil vapour and particulates before the air reaches sensitive tools or any breathing air equipment. After installation Avelair completed a full breathing air quality test which confirmed compliance with BS EN 12021 and provided the client with formal assurance of air purity and operator safety.

Responsible Condensate Management

Environmental compliance was another important part of the project. Compressed air systems naturally generate oily condensate which must be treated before disposal in accordance with UK legislation. As part of the upgrade, Avelair installed a condensate management and treatment system which ensures safe separation of oil from water and allows clean discharge in line with regulatory requirements. This protects the environment and ensures the client remains fully compliant with waste disposal obligations.

Long Term Reliability and Reduced Operating Costs

By replacing an outdated fixed speed system with the Avelair variable speed drive air compressor and a fully integrated air treatment package, the client now benefits from lower energy consumption, a reduced carbon footprint, stable high quality compressed air, certified breathing air compliance, reduced maintenance requirements and improved long term reliability.

A Future Focused Investment

This case study demonstrates how a carefully engineered compressed air upgrade can deliver immediate improvements in performance safety and running costs. With the British manufactured Avelair VSDR 22 at the centre of the system the client now has a dependable and efficient compressed air solution designed to support their operations for many years.

For more information on Energy Efficient Compressed Air Upgrade talk to Avelair Compressed Air Solutions