Success Story | Manufacturing

Plastic and cellulosic materials manufacturer Futamura, has made significant energy savings and CO₂ emissions reductions by upgrading ageing compressed air equipment with three KAESER energy-efficient rotary screw compressors and a SIGMA AIR MANAGER 4.0 compressed air management system, at its production site in Wigton, UK.

Futamura’s compressed air equipment consisted of four ageing reciprocating compressors and two ageing air receivers, alongside a heated adsorption dryer that was unreliable and kept breaking down. The expensive desiccant in the dryer required regular replacement and was changed many times in its short four-year life. It was clearly time to make a change. 

Sean Jackson, Engineering Maintenance and Resource Planner for Futamura turned to KAESER partner HPC’s authorised distributor - Lakeland Fluid Power - for a solution.

“It was clear that Futamura could make significant energy efficiency savings, and consistently more reliable compressed air with a constant pressure and consistent quality,” said Sean Jackson. “There was also the opportunity to make considerable energy savings by using compressor heat recovery to preheat our manufacturing process water.”

Futamura engaged with Lakeland Fluid Power, their local HPC authorised distributor, in addition to another nationally known compressor manufacturer. “Immediately we felt very comfortable with Lakeland Fluid Power, who listened to our requirements, before proposing a solution based upon these requirements,” said Sean Jackson. 

Sean Jackson also looked at, and compared, the compressed air system equipment of another customer using KAESER, with that of a customer using a different brand. “From an engineering perspective the KAESER unit stood head and shoulders above the other brand”, said Sean Jackson. 

While the other brand had similar energy saving predictions, “the build quality on the KAESER was far superior”, he said.

We could clearly see that as a result, the longevity of the KAESER equipment would last significantly longer and be more reliable throughout the life of the equipment, practically after any warranty has expired.

Sean Jackson, Engineering Maintenance and Resource Planner for Futamura

The first step for Lakeland Fluid Power, after discussing Futamura’s requirements, was to data log the existing compressors’ duty. To do this, Lakeland Fluid Power utilised KAESER’s computer-aided Air Demand Analysis (ADA) to determine the compressed air consumption and associated energy consumption, costs, and CO₂ emissions. 

Then, using KAESER’s Energy Saving System (KESS), HPC was able to simulate the existing annual air consumption, totaling more than 2,500,000 kWh with an electricity cost of £250,000 (GBP) per year. Using KESS, HPC then simulated various improved options and selected the best energy performing compressors to meet the customer’s air demand profile. 

Lakeland Fluid Power and HPC were able to look at the various KAESER compressor sizing options to select the best one to ensure the highest energy savings and the lowest specific power resulting in lower operating costs and reduced CO₂ emissions.

“In the end there was no choice other than to award Lakeland Fluid Power and HPC the contract", said Sean Jackson. "Lakeland Fluid Power listened to our requirements, put forward a proposal that exceeded these and had the competence, professionalism and experience to project manage the installation and commissioning. Furthermore, they are local, and we take pride in supporting local businesses with the added benefit that Lakeland Fluid Power is able to provide first rate prompt local service when we need them most.”

HPC and Lakeland Fluid Power then supplied and installed a combination of three KAESER fixed and variable speed rotary screw compressors, with a KAESER SIGMA AIR MANAGER 4.0 (SAM 4.0) compressed air management system, operating at a constant pressure of 6.9 bar (100 psi) despite the varying demand, to reduce wasted and unnecessary energy consumption.

Once installed and operational, the KAESER SAM 4.0 ensured the compressors operated with the best efficiency, minimising specific power, and continuously recording the air consumption. Lakeland Fluid Power then uploaded the air consumption data back into KESS to confirm that the predicted energy savings had been achieved. 

HPC and Lakeland Fluid Power exceeded the annual savings originally projected: 

• Reduction of energy consumption: 973,190 kWh
• Savings in energy costs: £97,318 (GBP) 
• Reduction in CO₂ emissions: 2,267 tonnes
• Specific power: a combined compressor specific power as low as 5.63 kW/m³/min.

In addition, Lakeland Fluid Power was able to dramatically cut the annual maintenance costs - giving Futamura peace of mind - with the KAESER compressed air equipment covered under the 5 Year HPC No Quibble Warranty. And there will still be more savings to be made. “We are now in the process of connecting process water to the heat recovery of the compressor” , said Sean Jackson. “This water will then be preheated by the compressor, dramatically reducing our gas consumption with predicted further savings of £100,000 (GBP) per annum.”

In the end there was no choice other than to award Lakeland Fluid Power and HPC the contract. Lakeland Fluid Power listened to our requirements, put forward a proposal that exceeded these and had the competence, professionalism and experience to project manage the installation and commissioning.

Sean Jackson, Engineering Maintenance and Resource Planner, Futamura