Pearl Leather in Johnstown, NY uses compressors for process and control air in their leather treamtent operations. The raw cowhide that enters this 200,000 square foot facility will be treated and sprayed and will leave as brightly colored leather headed for the automotive industry. The plant operates two 8-hour shifts per day, 6 days per week. Pearl’s compressed air usage varies constantly depending on the number of processes operating at any given time as well as shift change fluctuations.

The plant’s air flow requirements range from 150 cfm to over 500 cfm at 90 psig. Pearl’s compressed air system included two 100 hp rotary screw compressors. They didn’t really know they needed a new compressor until Paul Sedal, from Kinequip an authorized representative for Kaeser Compressors Inc. stopped by on a routine sales call. “I saw several opportunities for improving system performance without even adding equipment,” commented Paul a trained and experienced Sales and Service Representative. “After a complete review of the system and the facility’s air demand, we found the units ran constantly but at less than full load: consuming valuable electricity without producing compressed air.”

Paul recommended Kaeser’s Sigma Frequency Control (SFC) variable speed drive compressor. Based on positive previous experience with Kaeser compressors, Pearl Leather President John Ruggerio agreed and purchased the SFC 132 to help reduce energy costs and peak demand charges. Designed with Kaeser’s oversized and optimized Sigma Profile airend and the unique Sigma Control system, the SFC can efficiently meet fluctuating air demands while maintaining a constant pressure of +/- 2 psig. The one-to-one direct drive with maintenance-free coupling allows the SFC to produce exactly the amount of air required with out idling. The 180 hp SFC 132 unit was installed, and easily handled the same load as the two old 100 hp units plus. It is currently running at between 50-80% load. Reviewing their monthly energy consumption, Pearl has seen a 20% reduction in kwH usage.

“Plus we’ve had no downtime, and the maintenance on Kaeser units is just so simple” commented Ruggerio, “The SFC is an excellent investment.”

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