Packaging producer saves €28 000 per year by installing Optimizer 4.0
A local manufacturer of consumer packaging reached out to Atlas Copco to identify potential energy-saving solutions and stay in line with the company's global sustainability goals.
The Challenge
The customer wanted to reduce the facility's annual energy consumption by 7%. Given the compressed air system accounts for a significant portion of the facility's electricity costs, the customer contacted Atlas Copco.
The Solution
The Atlas Copco team went on site and used a Data Logger to capture real-time compressor data to create a simulation of the customer's potential savings. The customer received a detailed AIRScan report, outlining all measurement data and an action plan.
Based on the simulation, the team proposed installing an Optimizer 4.0 Central Controller. The Optimizer 4.0 is designed to reduce load cycles and match energy consumption to actual power demand, which helps to maximize efficiency.
To show the potential benefits without any initial costs for the customer, the Optimizer 4.0 was installed via a Try & Buy program. During a four-week trial period, the compressors operated under local control for two weeks and then switched to central control. The results from the trial period are significant.
The energy consumption and CO₂ emissions both decreased by 16.5%, despite a 3.5% increase in air volume.
The Specific Energy Ratio (SER) decreased by 19.3%. This indicates greater energy efficiency, which was an important KPI for the customer.
The Outcome
The data from the trial period is used to calculate the annual savings. Thanks to the Optimizer 4.0, the customer saves 446 000 kWh per year, equal to a cost reduction of IDR 550 000 000 / EUR 28 000 per year. This way, the payback period for this investment is around two years. In addition, the customer achieves an annual reduction of 447 tons of CO2 emissions.
