Compressed air is an essential part of any packaging operation; it is typically used in large amounts across many applications and different machines. Optimising consumption can lead to major costs savings.
SMC is a global supplier of pneumatics, and its energy conservation group manager, Bill Blyth, said the company’s Airmas technology and its air management system (AMS) can provide data on factories' compressed air efficiencies on existing machinery and processes.
“We take into consideration the two elements of compressed air energy. Namely, pressure and flow. This improved air management can be installed on existing lines to assist with controlling energy,” Blyth said.
SMC fields a team of engineers that can establish how much air is being used, the energy consumption profile, and what can be achieved.
One example of how this works can be seen in a food producer in Victoria. This company used a high-speed filling and case-packing machine that consumed large volumes of air.
SMC’s team conducted tests during production, resulting in real-time results without affecting operations. Typically, SMC introduces new technology alongside the existing air-control to ensure there is no interruption to production while optimum results are achieved.
Blyth said, “When you analyse the air consumption profile graphs it becomes very obvious where the inefficiencies lie and where you are using much more than you need.”
Typically, readings indicate excessive flow rate, artificial demand, rapidly changing flows, high pressure drops, and non-productive consumption.
The analysis revealed that the food producer in Victoria could reduce its existing 700kPa to 500kPa, reducing the flowrate by about 30 per cent.
“Using standard SMC componentry, correctly applied and configured to provide the AMS delivers value and a wealth of data to the customer,” Blyth said.
“Data which helps them to achieve and, importantly, retain the saving and reduce bottom line when it comes to compressed air energy usage.”
Blyth said there are some standard components that need to be in place.“These include strategically placed monitoring and compressed air pressure and volume control devices and technology. This forms the basic bones of the AMS system,” he said.
“From here, we test the compressed air profiles and through adjustments we are able to accurately match the most efficient air profile using standard componentry to the existing system to deliver the desired outcome.”
Blyth said the key factors that the SMC energy conservation team considers during the process to establish a healthy system include controlled flow and pressure; most efficient demand profile; the elimination of artificial demand; and monitoring continual waste leakage.
By running the live trials with the customer, the team configured an AMS from standard components to suit the factory and machine layout.
SMC is encouraging customers to get in touch to assess their current air consumption and look at ways to improve their savings. “A little goes a long way and we are here to assist every step of the way,” Blyth said.
SMC is a member of the Australian Packaging & Processing Machinery Association (APPMA).
