Case StudyKraft Foods' Savings
JetAir Saves Kraft $300,000 replacing compressed air applications!
The JetAir Technologies' engineering team designed a custom solution that included a JET-1 high-speed motor and blower, Variable Frequency Drive (VFD), and four custom adjustable-mount nozzles. The JET-1 Direct-Drive technology enabled adjustable operation speeds of up to 20,000 RPM, creating adjustable flow rates of up to 750 CFM at pressures of 2.3 PSI. the compact footprint of the motor and blower enabled it to be located within feet of the application via 3" diameter (75 mm) hoses to the adjustable nozzles. The nozzles were then mounted at each corner of the guide rails (bottom/top-left, bottom-top-right) at the beginning of the gap. the custom mounting application and nozzles provided the soft drink bottling manufacturer adjustable air directional flow, while the VFD provided air flow and pressure adjustability.
JetAir Technologies' engineering testing of the custom solution demonstrated significant operational and energy savings. While the system originally consumed 22.7 HP (18 kW), JetAir Technologies' custom JET-1 blower solution enabled a true energy consumption of only 3 Hp (2.2 kW). this represented an energy reduction of 20 HP, or an 87% true energy consumption savings. Based upon the soft drink manufacturer's production cycle and kW per hour rate, the JET-1 custom solution's energy costs were estimated at only $970 per year (including maintenance), resulting in a total yearly savings of $3,560. This drastically reduced the soft drink bottling manufacturer's annual energy costs by 80%. These energy cost savings offered an estimated 65% return on the investment in the first year, and 125% ROI in two years.
Once installed, the compressed air and energy savings and the operational benefits were immediate. "It was quieter. It was saving his compressed air and saving horsepower," said Scott Lynn. "They ran power to it, set it up, turned it on, and haven't had any problems. When I called to follow up with them, the plant engineer told me it was much quieter than the old system."
The soft drink bottling manufacturer's installation of the JET-1 blower system eliminated the "innapropriate use of compressed air" (as defined by the DOE's Compressed Air Challenge), effectively reducing the amount of compressed air bled to atmosphere. This reduction of energy waste translated into a dramatic 80% reduction in yearly energy costs, lowering monthly costs from $380/mo. to $80/mo. As an added bonus, the efficient and streamlined design of the JET-1 blower system eliminated the high-pitched operational noise emitted by the old gap transfer system much to the plant engineer's appreciation.
"Its like printing money," said the leading soft drink manufacturer's plant manager.
Loss of compressed air to the atmosphere represents a significant energy and cost waste that can easily be eliminated with efficient, alternative solutions. High-speed centrifugal blowers offer an environmentally appropriate, effective and cost conscious alternative to compressed air. Realization of these energy and cost savings, however, begins with a compressed air utilization assessment. As demonstrated by the leading soft drink bottling manufacturer's experience, reassessing your compressed air usage may offer significant and immediate compressed air, energy and cost savings. With rising energy costs and environmental concerns, mitigating your company's energy use and environmental impact is imperative in identifying savings opportunities. Alternatives like high-speed centrifugal blowers offer an opportunity to operate more efficiently, effectively reducing your environmental impact and increasing your savings.