On reviewing the performance of the compressed air system at its Blackburn site in early 2015, Tensar saw an opportunity to improve productivity, reduce maintenance outage frequency and meet carbon reduction targets. This was confirmed following an energy audit of the compressed air installation carried out by Atlas Copco who identified the potential for significant energy savings. The audit recorded the annual electricity cost to run the existing compressed air system as just over £61,000. By comparison, the recommended replacement system’s equivalent cost of consumption was about £39,000, representing an annual saving of over £22,000. In addition, the calculations revealed a significant potential carbon footprint reduction of 141 tonnes of CO2.
The new Atlas Copco installation comprises a GA 37 VSD FF full-feature rotary screw workplace compressor with integrated dryer, filter, ancillaries and Mk5 Elektronikon graphic controller that provides full performance monitoring. This VSD-driven machine supplies up to 185 cfm of 13 bar compressed air to match the variable demands of Tensar’s manufacturing equipment.
The installation was completed with two fixed speed GA 37 FF full-feature compressors, with each machine supplying up to 243 cfm of compressed air at 7.4 bar. For optimum performance and process optimisation, the combined compressed air system is centrally controlled by an ES41 unit programmed to match Tensar’s shift working and workload requirements.
Commenting on his company’s sustainability programme and the benefits of the new compressor installation:
The Atlas Copco system has brought a new level of reliability and energy saving opportunity to our manufacturing output. What’s more it has enabled us to meet our commitment to significantly reduce our carbon footprint.”
For over 30 years, Tensar International has designed and manufactured sustainable construction solutions, such as its geogrids and geotextiles products and systems. Compressed air performs a vital role in the manufacturing processes for these products, not only for air cylinder actuation duties but also polymer materials extrusion and stretching operations.
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Tensar International supplies geosynthetic products and provides proven practical solutions for poor soil conditions affecting the cost of railways, roads and paved areas. The company also offers products for earth retaining walls and slopes, subgrade improvement and stabilisation, foundations, reinforcement of asphalt to extend pavement life and erosion protection products for soil slopes and waterways.
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 service 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.
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