In a bid to meet production demands for improvements in energy efficiency and air quality, insulation board manufacturer Celotex has replaced its existing compressor installation with an Atlas Copco full-feature, variable speed drive, oil-free compressor together with a heat regenerative IMD dryer. The result is reduced energy consumption and improved air supply quality within the manufacturing plant. The positive environmental impact of the new installation has also been a contributory factor in gaining the company its ISO 14001 accreditation.
Celotex, based in Hadleigh, Suffolk, is recognised as the UK brand leader within the PIR (polyisocyanurate) category of insulation materials*, a range of products considered by the construction industry to be the most cost effective and thermally efficient form of insulation. Dry compressed air is an essential factor in the continuous production process for insulation board assembly, which sandwiches PIR foam between two layers of aluminium foil or mineral glass tissue facer.
The decision was made to replace the two existing Atlas Copco ZT37 fixed speed, oil-free compressors and associated refrigerant dryers with a single air-cooled ZT75VSD FF machine incorporating an IMD heat-of-compression technology dryer. The installation provides the completely moisture-free air blanket required for the production process and, because of its variable speed drive feature that matches output to production demands, is a major factor in reducing energy consumption.
“I was very impressed with the speed and quality of Atlas Copco’s installation operation. It allowed us to make a completely seamless switchover from the old plant to the new without any interruption to the production process. As for the projected energy savings, with the energy-saving VSD operation of both the compressor and integrated dryer unit, it looks like we can expect to gain at least £6,000 per annum over the next three years.”
Atlas Copco’s Full Feature concept is a total installation − the compressor is a pre-wired and pre-piped solution, ready for use ‘out of the box’. Integrating the IMD dryer and its variable speed drive enables the compact package to supply high quality dry compressed air at the lowest cost. The IMD adsorption dryer eliminates the moisture before it enters the air net to ensure a reliable process and a contamination-free end product.
No external energy is needed to dry the air, and as the dryer needs no purge air, no compressed air is wasted. The pressure drop through the dryer is minimal, which again cuts down its operating cost. The overall effect is to generate substantial savings in comparison to conventional types of dryer operation.
Developed and published by ISO (the International Standards Organisation) the ISO 14001 standard specifies requirements for organisations that wish to achieve and demonstrate sound environmental performance. These requirements compel the applicants to control the impact of their activities, products or services on the environment by implementing an environmental management system.
Explaining the benefits of his company's comliance with the ISO 14001 standard:
“It fulfills core requirements for doing business within many public and private sector markets. It also demonstrates a responsible attitude and our environmental commitment. What’s more, accreditation adds stature to our corporate image with both existing and potential customers, portraying a clear message to all concerned parties that this is a company devoted to high standards and continual improvement.”
*- Celotex's new premium performance insulation is the only PIR to achieve the landmark lambda value, an 'A+' rating when compared to the BRE Green Guide 2008, British Board of Agrement validation and Class O fire performance.
Atlas Copco Compressors is the GB sales and service operation of the Atlas Copco Group providing oil-free and oil-injected stationary air compressors, gas and process compressors, vacuum pumps, turbo expanders, nitrogen generators, air treatment equipment (such as compressed air dryers, coolers, and filters) air management systems, and custom designed engineered packages.
Atlas Copco Compressors’ sales and distribution network means that specialist compressed air advice and service is always within easy reach. A team of over 80 service engineers operates across the country, to ensure maximum running efficiency and minimum downtime at its customers' sites.
In the United Kingdom, Atlas Copco also handles the sales and marketing of construction and mining equipment, portable compressors and electric power generators, industrial power tools and assembly systems – all backed up by a nationwide sales, distribution, service and maintenance network.
Atlas Copco is a world-leading provider of sustainable productivity solutions. The Group serves customers with innovative compressors, vacuum solutions and air treatment systems, construction and mining equipment, power tools and assembly systems. Atlas Copco develops products and services focused on productivity, energy efficiency, safety and ergonomics. The company was founded in 1873, is based in Stockholm, Sweden, and has a global reach spanning more than 180 countries. In 2015, Atlas Copco had revenues of BSEK 102 (BEUR 11) and more than 43,000 employees. Learn more at www.atlascopco.co.uk/compressorsuk.