Specialist chemicals manufacturer Sika Limited improves productivity with remotely monitored compressed air and nitrogen system
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Sika Limited has virtually halved its batch transfer time after installing a centralised and remotely monitored compressed air and nitrogen system from Atlas Copco. The system, which was installed, and is being serviced, by Atlas Copco subsidiary Compressor Engineering, is proving essential in the safe and efficient production procedures at the company’s manufacturing facility in Preston, UK. Furthermore, it has allowed full centralisation between adjacent plant installations and provided capacity for expansion.
Sika Limited is a part of the global Sika Group, specialising in the manufacture and supply of chemical-based products serving construction and industrial markets. The company operates out of two manufacturing facilities and five sites including Ireland. The six –acre site in Preston, Lancashire is home to the production of Sika’s Liquid Applied Membrane products. Over the years, Sika has made significant investments in both plant and premises, of which the Atlas Copco system upgrade is the latest development.
In Sika’s production processes the batch mixing procedure for large volumes of liquid materials is conducted under vacuum in vessels with capacities in excess of 5,000 litres. Batch transfer operations involve removing the vacuum under a nitrogen atmosphere in equally large volumes. The new utilities system, with increased capacity, allows more rapid generation and availability of the blanketing gas. This ultimately reduces batch transfer times and virtually halves the transfer cycle duration; thus, improving productivity and the energy efficiency of the system.
The equipment upgrade programme was initiated after a review of the performance of the site’s entire compressed air and nitrogen system with a view to improving productivity. Following this internal assessment, it was decided that the original installation lacked the capacity to meet peak production demand in the future, with upgrades to the existing equipment deemed to be impractical due to the unavailability of spare parts. The fact that two separate compressor systems were competing with each other to achieve the required demand was also judged to be inefficient from an energy management perspective.
Although potential energy savings alone provided justification for a new equipment purchase, the primary objective was to re-establish system reliability, ensure adequate back up capacity and deliver a high level of service. Commenting on the necessity for upgrading the plant, Lisa Baines, Operations Manager explained: “It was clear from the beginning that the old system could not cope in terms of capacity, quality or reliability. We also had to pay due regard to the power loading aspect as a cost component.”
The entire system is fitted with Atlas Copco’s SMARTLINK data monitoring programme, which intelligently gathers, compares and analyses data to increase maintenance and service efficiency. SMARTLINK provides Sika UK with a complete insight of its compressed air and nitrogen production, helps to predict potential problems and shows how and where operations can be optimised, and energy can be saved.
Commenting on the benefits of this major improvement, Lisa Baines explains: “Capacity, reliability, safety and productivity – every element of the operation has plus points.”
Air compressors Nitrogen and oxygen generation systems Compressor Technique Chemical & petrochemical Application story United Kingdom
Editor's notes:
Atlas Copco is a world-leading provider of sustainable productivity solutions. The Group serves customers through its innovative compressors, vacuum solutions, generators, pumps, 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 2017, Atlas Copco had revenues of BSEK 86 (BEUR 9) and about 34,000 employees. Learn more at www.atlascopco.co.uk/compressorsuk
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, blowers, 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 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.
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For further editorial information contact Chris Butcher on 01582 390980.
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Telephone number for publication: 0800 181085 E-mail address for publication: compressor.sales@uk.atlascopco.com
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