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A South American trailer manufacturer reduced their energy usage by 9% by installing an Optimizer 4.0 central controller. Due to its advanced controlling algorithm the Optimizer 4.0 optimizes the use of multiple compressors in the compressor room, reducing the SER (Specific Energy Requirement) and pressure band with significant energy savings as a benefit.
The Challenge
The customer had their own developed sequencer system to control their compressors. However, they were regularly facing production downtime due to insufficient pressure caused by big pressure drops at the production line. This triggered the customer to get in contact with Atlas Copco to find a solution.
The Solution
We installed an Optimizer 4.0 central controller to stabilize and optimize output flow and pressure of 11 Atlas Copco compressors and 2 competitor units.
Through the "Try & Buy” solution there was no initial investment required by the customer.
The Optimizer 4.0 monitors the SER (Specific Energy Requirement) and pressure of the complete installation.
During the trial period we were able to monitor the pressure band, both with and without steering by the central controller
No central controller
With Optimizer 4.0
Thanks to the Optimizer 4.0 the pressure at control point was stabilized and reduced and we were able to meet the required air demand with only 11 compressors instead of 13. The competitor units were turned off as they had the lowest efficiency.
The Outcome
The customer had used their own sequencer system to manage the compressors, but, after testing, they liked our central controller better.
The installation's SER went down from 433 J/l to 393 J/l, saving 9% of electricity. This corresponds to a CO2 reduction of 42.6 Tons/y.
Annual energy cost savings amount to USD 13 000 (not including production losses).
The central controller also increases machine lifetime and production uptime. Maintenance costs are reduced due to the shutdown of two machines and the increased lifetime of the operating machines. In addition, extra space was freed up in the compressor room.
The customer was so satisfied with this Try & Buy that they bought a second Optimizer for another site, without requiring a trial.
The Savings
13.000USD/year
9% electrical savings/year
42.6tons/year CO2
Footprint reduction
2Machines eliminated
Bonus extra space
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