Jayakrishna Modern Rice Mill located in Tamil Nadu’s Kangayam, had been in the rice milling business for the last 30 years. During the initial days in Kangayam there were not many modernized mills and due to growth of this industry, modernization in this field became inevitable which meant getting the latest, energy-efficient machines.
The need
They were using the piston-type reciprocating compressor which consumed a huge starting current and the power drawn for the flow deliverable was also high. Also there was considerable unloading during normal operations.
The right fit
With the savings proven physically with a trial compressor, they bought the 25HP GA18VSD+ P compressor and it’s been in operation for more than a year. It has helped them realise a drastic power saving of 33%.
Why replace your compressor?
If compressed air is an essential part of your day-to-day business operations, and downtime would cost you considerably in lost production, then you should consider if your compressor needs to be replaced.
Before making your decision, let’s consider a few important factors:
While a new compressor may seem expensive initially, it’s important to consider the overall cost of ownership over its lifespan. The actual purchase price of a new compressor is only around 10% of the total cost, while energy contributes up to 80% of an air compressor's total life cycle cost.
Compressed air systems represent the majority of energy costs in the facility, as they may reach 20% of the total electricity bill.
These challenges urge many companies to review the cost-effectiveness of their compressed air systems and switch to a new and smart energy-efficient compressor model, so the cost of a new unit soon pays for itself in electricity savings.
When to replace an old compressor?
If you're deciding between covering the cost of a pricey repair or investing in an even more expensive replacement unit, here are some key reasons why replacing your compressor might be the better option:
- Years of use: Compressors typically have an average life span of 7-15 years, depending on the harsh local conditions. Normally, a user should consider compressor replacement from the 5th year.
- Decreased performance: Continuous use can affect the compressor's performance over time. If the air compressor is old and has been working for a long time, replacing it may be a good idea to improve efficiency and performance.
- Large electricity consumption: results in a high electricity bill.
- Air leakage: If there is a leak in the pressure system, it may be
better to replace the compressor. Air leakage leads to pressure loss and reduces the efficiency of the compressor.
- Frequent breakdowns & repairs: This is more likely to happen again, resulting in stopping the compressor & production in addition to the loss of money
- Repair history: If there is damage to the compressor components, it may be necessary to replace them. Damage to these components can cause the compressor to stop working.
- Parts availability: Finding replacement parts can be time-consuming and expensive for older models.
- Energy inefficiency: Newer compressors are more energy-efficient. Replacing your old compressor could lead to long-term energy savings if your old compressor is inefficient.
- Increased compressed air requirements: if you need more air or more compressor power for new applications, replacing it with a larger unit or newer technology would be ideal for meeting your requirements.
Atlas Copco offers a solution to replace your old compressors or fixed-speed machines
with more efficient and modern Atlas Copco VSD compressors.