Choosing VSD compressor technology has helped International Flavors & Fragrances (IFF), a leading global creator of flavors and fragrances for consumer products, achieve major energy savings at its UK manufacturing plant in Haverhill, Suffolk.
The plant is one of many IFF plants worldwide producing fragrances and flavors that are used in products such as beverages, sweets, dairy, savory products, as well as fine fragrances, beauty care products, detergents, and household goods. As part of a recent expansion the plant’s compressed air system was upgraded.
IFF had originally installed an oil-free, fixed speed ZT3A together with a ZT290 machine on a service contract at the site. The compressors provide 100% oil-free air for process instrumentation, the operation of pneumatic valves for powder transfer and plant-to-plant product conveying. The 100% oil-free design of the Z machines is vital to eliminate even the slightest risk of contamination within the sensitive production environment.
Performance logging of the compressors, carried out prior to the expansion, highlighted the fact that significant energy savings could be achieved with the installation of a single, variable speed drive compressor to replace both existing units. The ZT 160 VSD was selected for its ability to match compressed output to demand in variable full load/variable load production cycles and its wide turndown range. This single compressor alone can provide all the air for the site while the old ZT3A has been retained as a standby unit.
The ZT 160 VSD machine was supplied to IFF on a Service Investment Plan (SIP) contract rental arrangement that includes the Total Responsibility service provision. This gave IFF access to newer, more efficient technology, along with service, support and free site audits, but without capital investment.
“ We calculate that in the past year we have saved £10,000 pa on our energy bills and significantly reduced our carbon footprint. It’s a direct result of Atlas Copco looking after our interests under their Total Responsibility Plan. The plan lives up to its name. We get regular iTrak audits to monitor our compressed air use, and that means total peace of mind, plus full coverage of the unit including air ends, motor, electrical and electronic systems, coolers, etc. with fixed annual costs for the agreed period. It means Atlas Copco technicians providing us with regular maintenance, engineering improvements, and breakdown repairs and machine overhauls if necessary. ”