2013 Product of the Year finalists: Compressed Air
Finalists in the Compressed Air category for the Plant Engineering 2013 Product of the Year competition.
Compact, oil-injected rotary screw compressors
The GA VSD+ range of compact, oil-injected rotary screw compressors reduce energy consumption by 50% compared to a traditional load/unload compressor. The 7 to 15 kW (10 to 20 hp) GA VSD+ range, including a full-feature version with an integrated dryer, is also 15% more efficient than the previous generation and offers a 12% improvement in free air delivery. The range was designed with energy efficiency and customer needs in mind, with a motor that exceeds NEMA Premium efficiency requirements. The motor and drivetrain share a single drive shaft and are vertically aligned, reducing the total footprint by up to 55%.
Integrally geared centrifugal compressors
The TURBO-AIR NX 12000 line of integrally geared centrifugal (IGC) compressors optimizes flow and efficiency for the air separation, steel, mining, automotive, aerospace, and petrochemical industries. The robust and stout machine design features the MAESTRO Universal SP control system, a compact, high-performance lubrication system, five-axis milled impellers, a compression cooling system, tilting pad thrust bearings, horizontally split gas and oil seals, and variable inlet guide vanes. IGC compressors provide a wide operating range, can typically throttle back over 30% from design flow conditions, and ensure higher reliability as well as a decrease in lifetime maintenance costs due to the minimal number of rotating components.
Two-stage, oil-free rotary screw compressors
The 75 to 160 kW air cooled CompAir D-Series of two-stage, oil-free rotary screw compressors feature flow rates between 8.88 and 23.56 m3/min. The D-Series offers air purity that meets the most stringent standards, has been certified ISO 8573-1 Class 0 (2010), and is silicone-free. Ideal for the pharmaceuticals, food and beverage, chemicals, and electronics industries, these compressors deliver outstanding reliability for demanding applications, state-of-the-art performance, and in-depth control from a Delcos XL controller. The design of the D-Series lowers lifecycle costs by working at constant low temperature levels, maximizing energy savings up to 25%.
Flat air nozzle
The 1-in Flat Super Air Nozzle produces a flat 1-in.-wide airstream with a strong blowing force of 9.8 oz when mounted 12 in. from the target. The unique design of this super-efficient nozzle makes it an ideal fit for both tight spaces and tight budgets. The 1-in. Flat Super Air Nozzle maximizes entrained airflow while reducing noise levels. A precise amount of air is released through the 0.0150-in. air gap opening that is set with a stainless steel shim positioned between the body and removable cap. The airstream pulls in surrounding room air to product a wide, forceful stream of high-velocity, laminar flow.
Air-cooled, oil-free screw compressors
The EnviroAire T/TVS Series of air-cooled, fixed and variable speed screw compressors range from 75 to 160 kW and are completely oil and silicone free. ISO 8573-1 Class 0 certified, the EnviroAire T/TVS Series offers improved efficiencies and are manufactured to meet the precise requirements of a diverse range of industries. Designed and built for continuous use in demanding application areas in up to 45 C ambient temperatures, the EnviroAire T/TVS Series uses a Gardner Denver designed and manufactured two-stage air-end that ensures exceptionally low power consumption while providing the highest outputs with absolute reliability and performance efficiency.
Rotary screw compressors
The BSD Series of rotary screw compressors are available in 40, 50, and 60 hp with flows from 157 to 294 cfm and pressures up to 217 psig. These compressors deliver energy efficiency through a combination of true direct drive design, premium efficiency motors, and lower internal pressure differential and optimized air-ends. Specific power is improved by up to 6%, and the built-in heat recovery options add to the energy savings capabilities. The BSD Series features include an enhanced cooling design, eco-friendly filter element, integral moisture separator with drain, and an electronic thermal management system. They also come standard with Sigma Control 2.
The Com-paK BB69C/BB89C blowers from Kaeser Compressors are fully integrated units that arrive on-site ready for use and include a motor with an automatic V-belt drive tensioning device, inlet/outlet silencers, a full sound enclosure, starts/drives, a full complement of sensors, and an onboard controller. These 5 and 20 hp units are designed, built, and tested to meet international and domestic performance and safety standards, and are available in both STC (wye-delta start) and OFC (variable frequency drive) versions. The BB69C and BB89C include Sigma Control 2 with Omega Control software. ModBus, Profibus, Profinet, and DeviceNet interfaces are available.
High-capacity refrigerated dryers
The TK-TM Series of modular high-capacity refrigerated dryers are ideal for large compressed air systems and utilize digital scroll refrigeration technology to offer effective energy savings. These water-cooled dryers have flow capacities that vary from 1,250 to 12,500 scfm, based on combinations of 2,500 and 1,250 scfm modules. Each module has air-side isolation valves, a cooling water control valve, and cooling water isolation valves, allowing individual modules to be serviced without disrupting the system airflow. Each module in the TK-TM Series features its own electrical disconnect switch for ease of maintenance.
Case Study Database
Get more exposure for your case study by uploading it to the Plant Engineering case study database, where end-users can identify relevant solutions and explore what the experts are doing to effectively implement a variety of technology and productivity related projects.
These case studies provide examples of how knowledgeable solution providers have used technology, processes and people to create effective and successful implementations in real-world situations. Case studies can be completed by filling out a simple online form where you can outline the project title, abstract, and full story in 1500 words or less; upload photos, videos and a logo.
Click here to visit the Case Study Database and upload your case study.
Annual Salary Survey
In a year when manufacturing continued to lead the economic rebound, it makes sense that plant manager bonuses rebounded. Plant Engineering’s annual Salary Survey shows both wages and bonuses rose in 2012 after a retreat the year before.
Average salary across all job titles for plant floor management rose 3.5% to $95,446, and bonus compensation jumped to $15,162, a 4.2% increase from the 2010 level and double the 2011 total, which showed a sharp drop in bonus.