Problem: Nitrogen gas costs for a prominent peanut and snack foods packager were too high.
Solution: Incorporating the nano GEN2 Series into their compressed air system.
Outcome: Reducing nitrogen gas costs by 83% and improving overall performance. Here’s how it happened.
Application Review – nano GEN2
So what happens when your air compressor goes down? Hopefully, your backup compressor fires right up and your production doesn’t miss a beat. But things don’t always work out that way. At some point in time, you may have to get a rental compressor. Having a rental air compressor plan in place will save you a lot of time and frustration. Here are a few things to think about ahead of time:
- Where would this compressor be installed? Do you have room and easy access in your current compressor room, or will it need to be installed in a remote location of the plant?
- What are your pressure and CFM requirements? Knowing this ahead of time will expedite the process of finding a rental.
- How would you incorporate the rental into your existing compressed air system?
- Will you need an extra hose to connect? If it’s necessary to put the compressor in a remote location, make sure you know how much hose you’ll need to tap in to your plant system.
- You’ll also need extra wire to run power to the compressor. Knowing how much you need will save time.
- Keep air quality in mind as well. If you have to locate the rental away from your other air treatment equipment, consider a dryer and filter to go along with the rental compressor.
- If it’s going to be a long-term rental, be sure to find out up front who is responsible for the routine maintenance and any repairs necessary on the rental.
At Lewis Systems & Service Co., Inc., we have a wide variety of rental compressors available-from reciprocating to large flow oil-free rotary screw compressors. We also have NFPA 99 medical compressed air and vacuum packages available for short – and long-term rentals. Contact us and we’ll be happy to help you out.
With colder weather coming soon, compressed air systems that are subject to lower temperatures may deal with slow starting, possible control line freeze problems, and condensate lines freezing. To help prevent some of these problems, heat lamps can be installed close to the lines to prevent freezing. Also, applying heat tape with a thermostat to control lines and condensate lines is a great way to protect your equipment located outside. However, keep in mind that anything installed on the lines themselves might have to be removed when the equipment is being serviced.
Here is a basic cold weather diagnostic outline:
- Check insulated areas and make sure the heat is staying inside and the cold is staying outside.
- Also check any weather stripping and replace areas that are worn out and not working properly.
- Check condensate drains throughout your system for proper operation. Excess water in your lines and freezing temperatures are not a good mix.
- Check the intake for your air compressor. If it’s exposed to the outside elements, your inlet air filter can be damaged from ice and snow.
- Compressed air receivers should be protected as well. If condensate is allowed to collect at the bottom of the tank it can freeze. Insulate any outside pipes feeding the tank as well as the condensate drain for the tank.
- Kind of a no brainer here, but make sure your compressed air dryer and compressed air filters have been serviced and are operating correctly. Their job is to remove condensate from your compressed air system. The less condensate in the system the less there is to freeze and cause problems.
Contact us today if you need any help with addressing your cold weather vulnerabilities. Taking these proactive steps now, can help prevent some major problems once it turns cold outside.
The piping system used to deliver compressed air throughout your facility is very important. Its material, age and condition affect both reliability and air quality.
Quick-lock aluminum piping is the world’s only totally metal push-connect piping system with many advantages over all current push-connect systems. It is the only push-connect system that fully complies with the ANSI B31.1 piping system code. No special tooling is needed to install the Quick-Lock system, and has electrostatic powder coating for all internal and external applications.
Piping made with iron will rust and corrode, creating buildup on the interior and reducing air flow capacity. This will also contribute to contamination and poor air quality for your downstream processes.
- They don’t rust or have scale buildup inside, eliminating contamination to avoid reduced efficiency due to pressure drops Much easier to modify than traditional black pipe
- Substantially lighter than steel
- Can handle a wide range of operating :.99 bar to 220 psi
- Can handle a wide range of temperatures: 4 F to 176 F
- Significant reduction in air leaks saves money in lost power
- Safer than plastic and will not become brittle
- never use PVC for compressed air
- Pipes are color coded for easy identification: air is blue, vacuum is grey and inert gas is black
- Versatile, tough and long-lasting metal fittings made of brass, plated with nickel
- Wide range of sizes for varying air flow needs: 14mm to 63 mm
- Advanced fittings eliminate the need for drilling into tubing
Remember: Plastic is for Toys. Don’t Settle- Choose Metal.
Download our Quick Lock Tubing Brochure or contact us today.
Travaini’s new series of compact, high vacuum packages are capable of a working vacuum level of 29.86. HgV and flow rates up to 2100 ACFM. This new design has been developed through a partnership with Bora Blowers and Travaini Pumps USA. Bora Blowers specializes in the manufacturing of boosters for pressure and vacuum applications. Leveraging Bora’s sophisticated electronics for controlling boosters, the partnership customized the technology to couple the liquid ring vacuum pump and the booster. This innovation, along with a unique sensor configuration, allows precise control and protection that traditional packages simply can’t offer.
FEATURES AND BENEFITS:
- Minimize the Absorbed Power: Compared to traditional liquid ring systems, energy savings could add up to over 30%. A 15hp package can provide deeper vacuum at higher volumes than a 30hp two stage liquid ring pump by itself
- Safeguard Your Processes: Our unique design and advanced controller protects critical processes with the ability to precisely set and maintain required vacuum levels. This optimizes the reaction to conditions and minimizes losses
- State of the art Technology: The DVD2 “Digital Vacuum Drive” controller and unique sensor configuration maintain even temperature by controlling compression rates. This prevents the elevated temperatures to protect the booster.
- Plug and Play: Multiple preset modes applied at Travaini provide a ready-to-use product. This saves you time reprogramming for different processes or shift changes. Additional adjustments are easy to make. This slide illustrates how a 10hp Liquid Ring Vacuum Pump operates alone (blue) and then how it operates with only a 5hp booster added, (red). The significant gain in capacity is presented in green. This 15hp package will give the same flow and deeper vacuum than a 30hp two stage pump.
- Chemical: Solvent extraction, gas evacuation from tanks
- Plastics: Degassing
- Pharma: Stabilization and controlled filtration / crystallization process
- Food Industry: Water evaporation, vacuum coolers
- Leather: Treatment & vacuum drying
In high volume, critical applications where strict control of high vacuum levels are imperative, these packages from Travaini are the logical solution. Lewis Systems will be happy to take a look at your current applications or help you with designing your next system. Contact us today.