A Magazine for the Production Industry
Quenching E'stel Water's thirst for high pressure compressed air technology
Prevention better than cure!
Efficiency shines Bright
Turnkey solution for green-star rated manufacturing facility
Industrie 4.0 compressed air maintenance
Weekly preventive maintenance checks
ADA & KESS deliver energy savings for Bright Print
Boxing clever Turnkey solution for green-star rated manufacturing facility
Prevention is better than a cure! Weekly air compressor preventive maintenance checks
Energy efficiency shines Bright ADA & KESS deliver energy savings
Rugged efficiency Introducing the MOBILAIR M235
Quenching E'stel Water's thirst for high pressure compressed air technology
Energy saving Next generation filters
Complete lifecycle efficiency Industrie 4.0 compressed air maintenance
KAESER COMPRESSORS Australia Pty. Ltd. 45 Zenith Road, Dandenong, VIC 3175 Tel. +61 3 9791 5999 , Fax. +61 3 9791 5733 E-Mail. firstname.lastname@example.org, www.kaeser.com.au
The publisher accepts no liability for manuscripts and photos submitted without request. Reproduction, including of excerpts, only permitted with written permission. E&OE. Information correct at time of print.
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Limiting the impact of rising power prices
Google ‘power prices’ and you will find an endless stream of articles on the persistent electrical price increases Australia continues to experience. This will come as no surprise as we all bear this onus first hand in of our respective operations. Encouragingly many manufacturers have long since been actively seeking ways to minimise the impact to their business, by introducing energy efficiency initiatives that are not only good for the bottom line but also for the environment. As the fourth utility in many manufacturing, processing and engineering operations, compressed air will be a significant energy consumer. In fact, if you look at the lifetime costs of a typical compressor, three quarters of it will be attributed to energy. So, how do we limit the impact of this cost to our business? By operating an energy efficient compressed air system. Selecting energy efficient compressed air equipment that is designed to meet the specific compressed air requirements of the application will certainly go a long way to achieving energy efficiencies. However, how the compressed air system is operated and maintained will also have a large bearing on how energy efficient the system remains in the long run. Intelligent compressed air management systems have long since been available and, acting as the central mastermind for the compressed air system, they are able to monitor and control the entire operation and proactively calculate and instigate the most efficient performance solution at that point in time. The result: a compressed air system that operates at its most efficient. But, that is only part of the story. As we have just mentioned, maintenance is also a key factor.
Peter Eckberg, Managing Director
interconnects man and machine, equipment and components. These advanced – Industrie 4.0 – controllers additionally allow for varying levels of involvement by external service providers. Through availability of compressed air system process data and the resulting analysis, it is possible to identify the perfect point in the future when the compressed air supply system should be maintained and serviced. This prevents costly periods of downtime, and allows compressed air system performance to be precisely matched according to demand throughout the entire life-cycle of the system. This combination of remote diagnostics and demand-oriented preventative maintenance ensures maximum availability and potentially reduces service costs by up to 30 percent. Subsequently, the overall energy efficiency of the compressed air system is increased. For a more detailed account of how long term energy efficiency can be realised, turn to page 8 to read more about complete lifecycle efficiency with Industrie 4.0 predictive maintenance.
In this edition, you will also find a round-up of some of our latest product developments – all designed and manufactured in Germany to provide our customers with ‘more compressed air Thanks to the dawn of Industrie 4.0, the ability of such advanced and more savings’, and you can also see how we have assisted a compressed air controllers has increased expediently. Based on number of our customers in efficiently meeting their compressed advanced digital information technology, Industrie 4.0 air requirements.
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Oji Fibre Solutions, a leading producer of market pulp, p efficient KAESER compressed air system in the develop packaging manufacturing facility in Yatala, QLD.
paper and fibre based packaging, opted for an energy pment of its new green-star rated corrugated cardboard
Turnkey solution: For green-star rated manufacturing facility
From fresh fruit and produce, meat, poultry, seafood and beverages to reseller and industrial manufacturing – the wide range of industries that Oji Fibre Solutions has been supplying innovative corrugated cardboard packaging solutions to, in Australia and New Zealand is immense. Oji Fibre Solutions is part of the pulp and paper division of Oji Holdings Corporation the fifth largest pulp and paper company in the world. As part of the company’s expansion to its packaging business in Australasia, Oji recently invested into the development of a new 5.8 hectare Greenfield site in Yatala, Queensland. Complementing the company’s existing manufacturing plants in Melbourne and Sydney, the Yatala site houses a newly constructed 2.4 hectare green-star rated manufacturing facility. From here Oji manufactures and supplies innovative corrugated cardboard packaging solutions to its customers throughout Queensland, northern New South Wales and the Northern Territory. As part of Oji’s commitment to delivering innovative and environmentally sustainable products, the new facility operates to a greenstar rating system. From daylight sensors and a lighting control system to a rainwater harvesting system, Oji implemented a number of initiatives that would assist them in reducing emissions and increasing energy efficiency throughout the operation. It is no surprise then that in designing and building the new manufacturing facility, they also chose to invest in the latest and most energy efficient manufacturing technology. Energy efficiency was therefore a key criteria for Peter Henley, the Engineering Manager at Oji, when selecting the compressed air system for the new facility. From material handling to the conveyor systems, pre feeders and corrugator, compressed air would be a key utility required throughout the manufacturing process. After considering a number of vendor packages, Oji chose to invest in a KAESER compressed air system, consisting of a KAESER CSD 85 series fixed speed rotary screw compressor, a CSD 125 SFC SIGMA frequency controlled rotary screw compressor, in addition to a comprehensive compressed air treatment package.
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The CSD series of rotary screw compressors from KAESER push the boundaries when it comes to compressed air efficiency in a number of ways;
selected as part of the compressed air package. As the lead compressor, it is responsible for supplying the sites initial requirements for compressed air.
They provide seamless communication between the SFC control cabinet and the compressor controller, thereby ensuring maximum efficiency at all times.
Developed by KAESER and continuously enhanced ever since, all CSD series models include the low speed SIGMA PROFILE rotary screw compressor block. Equipped with flow-optimised rotors, this achieves power savings of up to 15 percent compared with conventional screw compressor block rotor profiles.
In any compressed air installation where a frequency controlled compressor is installed, this will be the compressor that operates longer than any other unit within the system. The KAESER CSD SFC series models were therefore built with maximum efficiency in mind and are designed to avoid extreme high speed operation. This saves energy, maximises service life and enhances reliability.
The additional fixed speed KAESER CSD 85 series rotary screw compressor at Oji, therefore acts as the lag compressor. This means that it only starts up and produces compressed air when the demand exceeds that which the CSD 125 can produce alone. This therefore ensures that the fixed speed unit is not operating in a loaded state for extended periods of time. The result of this configuration for Oji is optimum energy efficiency, reducing power costs, by only producing the precise amount of compressed air required at any one time.
Energy efficiency is further maximised with the inclusion of an IE3 drive motor - which complies with and exceeds prevailing Australian GEMS regulations for 3 phase electric motors. In addition, the 1:1 drive design eliminates the transmission losses associated with gear or V-belt driven systems, as the motor directly drives the screw compressor block. The inclusion of the SIGMA CONTROL 2 compressor controller also enables compressor performance to be precisely matched to actual air demand thereby allowing additional energy savings. In order to meet the fluctuating demands for compressed air of the new manufacturing facility in the most efficient way possible, a frequency controlled rotary screw compressor was
Operating pressure can be consistently maintained with +0.1 bar. In turn, the consequent ability to reduce maximum system pressure also reduces energy costs. The relationship between pressure consistency and speed can be viewed directly on the SIGMA CONTROL 2 display. The soft rise in motor starting current from zero to full load without current spikes lead to an almost unlimited motor starting frequency (the number of possible motor starts within a given time period without overheating occurring). The continuously variable acceleration and deceleration significantly reduces component stress. All KAESER SFC packages are equipped with Siemens frequency converters.
Peter Henley commented; â€˜We have been using KAESER compressors for some time now on our other sites and they have proven to suit our application and be reliable and efficient in meeting our compressed air requirements. We have also found that they are well suited to operating in the Australian climate.â€™ The CSD series of rotary screw compressors from KAESER are available with working pressures 7.5 to 13 bar, motor power 45 to 75 kW and free air deliveries 5.50 to 12.02 m3/min with the fixed speed units, and 1.07 - 12.00 m3/ min with the frequency controlled units.
'...they have proven to suit our application and be reliable and efficient'
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Industrie 4.0 compressed air maintenance
lifecycle efficiency Significantly enhanced reliability, cost-optimised servicing, longer system service life and assured specific power are all benefits that compressed air users can realise with Industrie 4.0, needs-based maintenance… When it comes to compressed air production, intelligent contracting model-based solutions have been available for quite some time. These hybrid service bundles combine highly efficient, innovative products with intelligent services. These solutions have laid the foundation for Industrie 4.0 in the compressed air production sector, and thanks to new communications technologies and services, are now being further refined and improved. These solutions include the components of the compressed air station as well as peripheral equipment. They also include the many services that can be rendered throughout the entire lifecycle of the compressed air station, such as precision air demand analysis, optimal design for compressed air supply systems and regular maintenance and servicing; not to mention energy management options, as well as planning of new systems, expansion of existing ones and investment in replacement equipment. Let’s first examine the components. To take full advantage of their Industrie 4.0 capabilities, components must meet two sets of requirements: support efficient control when utilised in combination with other machines and also provide real-time operating data for monitoring purposes, able to forward all relevant data to master control systems. Modern compressors and compressed air treatment components are therefore equipped with internal controllers which are able to pass data to a master control system via interfaces. The data generated is first delivered to a master controller. This controller acts as an actual management system for the compressed air station as well as a central node for the forwarding of relevant data. Such advanced management systems 8 | KAESER report
must successfully meet some highly demanding conditions. Not least, they must be capable of efficient and predictive compressor control, taking into account a range of factors, such as switching and control losses. Another key requirement is the ability to handle the sheer volume of incoming data from the compressor station, which must be compiled and then sent on to a superordinate service centre. Multiple levels of functionality These advanced controllers allow for varying levels of involvement by external service providers, so operators can still choose to perform the maintenance, evaluation and servicing of the system themselves. In this case, the master controller is integrated into the operator’s control system and the data can be requested by any desired part of the company. Alternatively, system operators can opt for a conventional service agreement. Or, to take advantage of further services, they can choose a predictive maintenance service model, and then there’s the option of remote diagnostics. Real-time
monitoring of data enables immediate response to unusual operating statuses and lays the foundation for optimal service planning. Thanks to intelligent predictive tools, operators will already know what’s actually going to occur in the compressed air station. Such advanced solutions represent the highest level of operational reliability and offer some key advantages: Firstly, operators are released from the burden of performing maintenance and service on the compressed air station. This saves fixed costs in the form of payroll expenses, as well as the cost of investment in their own service management system.
Secondly, outsourcing allows customers to benefit from the very latest knowledge and expertise in the compressed air technology sector. The value of this should not be underestimated, as the field of compressed air engineering is now so complex that normal industrial companies are rarely able to maintain such high-level knowledge in-house.
in the near future, and if so, to take appropriate preventative measures.
Thirdly, outsourcing delivers clear-cut cost advantages. The data from the compressed air station is requested, transmitted and analysed in real-time. This of course translates into a huge amount of data, which, in turn, requires significant investment in IT in order to handle and utilise it. For most operators, such an investment would be neither possible nor economical.
The benefits from predictive maintenance agreements, however, extend beyond the guaranteed high availability of a compressed air system. For instance, lifecycle costs can be reduced by up to 30 percent as the compressed air specialists can adjust the energy performance of the compressed air station according to demand to ensure it operates at peak performance at all times. Needless to say, this increases the system’s overall effectiveness.
Always up-to-date Whenever desired, real-time monitoring gives the service provider a detailed picture of what is happening in the compressed air station. And, this is not restricted to the
main system components, but can be extended to peripheral equipment as well. If irregularities occur, a notification is automatically generated in the service provider’s service centre; this triggers preventative measures to avoid system disruption or failure. In addition, sophisticated algorithms allow specialists to predictively estimate whether potential disruptions may occur
Such usage or need based maintenance cuts costs and prevents system failures. Operators enjoy significantly enhanced reliability, cost-optimised servicing, longer system service life and assured specific power.
The usefulness of the data does not end with the service technicians who
optimise the systems: the service provider’s research and development department also benefits. Through analysis of how products behave during disruptions, they are able to identify patterns, and the causes of malfunctions – in order to ultimately further develop and optimise the components themselves and further enhance operational reliability into the future. Intelligent planning In most cases another key service is KAESER report | 9
required in order for operators to take full advantage of their compressed air system’s Industrie 4.0 capabilities: proper planning of the compressed air system. Such a service involves gathering all parameters and components relevant for compressed air production in a planning tool, which allows operators to systematically track every aspect of their compressed air system throughout its entire lifecycle. It also ultimately serves as the foundation for intelligent services, such as efficiency management and predictive maintenance. In the past, systems were usually mapped out on paper. The documentation was rarely kept together in one place. Moreover, subsequent modifications were not usually recorded or if so, this documentation was stored yet elsewhere. As a consequence, information regarding the compressed air station was seldom up to date and there was no single, centralised way of accessing the information. Opting for an intelligent planning tool is therefore a powerful way to record and maintain data correctly, quickly and completely, storing it securely and ensuring the information is always up-todate thanks to real-time transmission and evaluation. To a certain extent, with such an intelligent planning tool, it is even possible to integrate existing systems or those of different manufacturers, provided the compressors have a suitable microprocessor.
In terms of planning new systems, utilising an intelligent planning tool elevates optimal design of the compressed air station to a new level; it also ensures secure and efficient operation indexed to actual demand, both after and during commissioning. The data also act as an ideal resource that is always available whenever it is time for implementation of optimisation measures. Consistent and complete collection of all data for the compressed air station and its peripheral equipment also saves valuable time when it comes to expanding or reconfiguring the system.
Weekly air compressor preventive mai
Operators that take advantage of all the solutions on offer for their compressed air station enjoy highly efficient components and all of the benefits of precision planning. Yet the whole package is far greater than the sum of its parts: a stateof-the-art system in terms of energy efficiency; which in turn translates into the most significant reductions in energy costs currently possible; not to mention innovative services like predictive maintenance, which reduce other service costs throughout the system’s entire lifecycle – up to 30 percent based on common current costs. Energy efficiency monitoring also enables yet further savings over the system's lifecycle as continuous adjustment to fluctuating operating conditions ensures that the system always operates at optimal load.
Performing the OEM’s recommended daily and weekly maintenance checks is one very simply practice that can assist in operating a compressed air system at its peak performance. Here’s an example of the checks that are recommended for an ASK T SIGMA CONTROL Basic belt driven rotary screw compressor with integrated refrigeration dryer; On a daily basis; 1. Check the compressor display Check the display on the compressor controller for any relevant information such as service due messages or warnings, and carry out tasks punctually. In addition, listen for any unusual sounds. On a weekly basis; 2. Check belt tension Before checking the belt tension remember that touching rotating drive belts may result in severe bruising or even loss of limb or extremities. The cabinet should not be open while the machine is switched on. Therefore, prior to checking the belt tension, ensure that the supply power isolator is switched off and locked using a safe lock out/tag out procedure, and check that no voltage is present. Allow the machine to cool down. Check the belt tension and adjust as necessary. The tensioning device
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n is better than a cure!
This article has been taken from the KAESER Australia Blog kaeserknowhow.com.au
Visit our YouTube channel to see these tips in action! uses spring force to apply correct tension to the belts. Adjust the tension when the marker pin reaches the top of the elongated hole. Loosen the locking nut. Use the adjusting nut to adjust spring tension until the marker pin reaches the lower end of the elongated hole. Tighten the locking nut. Turn the pulley by hand so that all of the belt can be inspected for damage. Damaged belts should be immediately changed. Contact your compressed air service provider if the belts require changing. 3. Check the cooling oil level Most air compressors are designed to have a certain volume of oil circulating. If this volume decreases the internal temperature will increase which will ultimately lead to the compressor overheating and shutting down. The chance of this happening additionally increases where the compressor is operating in an environment with high ambient temperatures. The result would be premature wear as well as unplanned service requirements and downtime. The sight glass allows a risk-free reading of the cooling oil level. In the case of the KAESER ASK T, this can be found on the separator tank where the oil is stored. The oil indicator should be fully filled with oil when the machine is at standstill. However, the correct oil level cannot be seen at standstill. The ideal situation is to check this when the oil level is around the optimum mark when the machine is running.
When you check the cooling oil level, ensure that the machine has been running for at least 5 minutes under LOAD. As soon as the minimum level is reached, replenish the cooling oil. 4. Cooler: check the filter mat To check the filter mat, first make sure the machine is switched off. Carefully remove the filter mat from the retaining frame. Beat the mat or use a vacuum cleaner to remove loose dirt. If necessary, wash with lukewarm water and household detergent. Change the filter mat if cleaning is not possible or if the change interval has expired. Carefully insert the filter mat in the retaining frame. 5. Control cabinet: filter mat A filter mat is placed behind every ventilation grille. If the filter mats are clogged, adequate cooling of the components is no longer ensured. In such a case, clean or replace the filter mats. To inspect, ensure the power supply isolating device is switched off, the device is locked off, the absence of any voltage has been verified and the machine has cooled down. Carefully remove the ventilation grille and take out the filter mat. Beat the mat or use a vacuum cleaner to remove loose dirt. If necessary, wash with lukewarm water and a household detergent. Change the filter mat if cleaning is not possible or if the change interval has expired. Insert the filter mat in the frame
and latch in the ventilation grille. 6. Check the condensate drain To check that the drains are working, first ensure the machine is shut down and the Power LED lights. With one hand, lightly touch the condensate drain hose at the condensate drain. With your other hand, push and hold the <> key at the condensate drain for at least 2 seconds. As soon as the condensate drain opens, you will feel a short burst at the condensate drain hose. If you do not experience a burst, the condensate drain will need servicing. 7. Log tasks completed Finally, document all maintenance and service work completed, enabling the frequency of individual maintenance tasks and deviations from the OEM’s recommendations to be determined. !IMPORTANT! When working on a compressed air system remember that compressed air is contained energy. Uncontrolled release of this energy can cause serious injury, or death. The information provided above is for guidance only and refers to a specific compressor make and model. Only qualified and authorised personnel should perform daily / weekly maintenance tasks that have read, are conversant with and adhere to the safety instructions and section of the service manual applicable to maintenance of the piece of compressed air equipment. In addition, the relevant statutory and accepted regulations should be observed.
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ADA & KESS deliver energy savings
Bright Print Group, an award winning printer based in NSW, recently underwent a comprehensive Air Demand Analysis with KAESER Compressors which assisted them in selecting the most energy efficient compressed air system configuration to meet their current demand for compressed air.
Bright Print Group (Bright) is a family owned and managed national printer with operations in Sydney and Newcastle. Full colour printing, digital print, binding and finishing are just some of the superior printing services that Bright has to offer. Using the latest technology and sustainable printing practices, they are able to deliver a broad spectrum of end products to their customers, such as: business cards and magazines, to posters, point of sale materials, books and brochures. At Bright’s purpose built factory in Wetherill, NSW, compressed air is used extensively in the manufacture of these products. From the printing presses, laser cutters and guillotines to the laminating and the stitching and trimming machines, compressed air plays an integral role. In recent months, Bright has expanded its
operations by introducing wide format printing, as well as through the acquisition of a commercial print and promotional item company. Both of these developments have not only changed their demand for compressed air, but the company acquisition also meant that they inherited an additional compressed air system. Operating an energy efficient and lean manufacturing facility In light of these changes, it was clear to Debbie Burgess, joint Managing Director and fourth generation Bright printer, that in order to continue to operate an efficient manufacturing facility, the compressed air system needed to be assessed. As an ISO9001:2015 and ISO14001:2015 accredited company (the international quality and environmental standards respectively), operating an efficient facility is of paramount importance to Bright. So much so that the company has also implemented a number of further environmental initiatives over the
years. Most recently all employees underwent training to achieve Level III Lean Manufacturing certification. This initiative assisted the company in developing a super-efficient manufacturing facility. It is no surprise then that the first step they took in order to assess their compressed air requirements, was to undergo a comprehensive compressed air demand analysis audit. As Burgess said; ‘we decided to have an audit done so we could better understand what we needed in order to efficiently operate the compressed air system’. Long standing compressed air supplier - KAESER Compressors – was therefore invited to perform a complete Air Demand Analysis (ADA) on the existing compressed air system that would then be analysed using the KAESER Energy Savings System (KESS). Saving energy and money with ADA and KESS The first stage when planning any compressed air system is to determine the actual air demand in order to meet this as efficiently as possible.
The computer-aided ADA from KAESER, allows meaningful and accurate data to be gathered regarding compressed air system performance. By simply wiring the ADA logging equipment to the existing compressors electrical cabinet, KAESER is able to pick up various digital signals for load and motor running, as well as logging the pressure. From this information, the true compressor performance can be established. The resulting air consumption profiles gathered from the ADA are then analysed using the KESS. This advanced s o f t w a r e d e v e l o p e d by KAESER Compressors, doesn’t simply come up with one solution, but offers the most efficient and economical one from several possibilities. The ADA and KESS together can provide a realistic forecast of the energy savings that can be expected from a proposed compressed air system. An effective compressed air system should provide maximum availability at all times. Particular attention is therefore given to ensure that the system solutions presented are designed to deliver outstanding dependability and performance. In Bright’s case, precise data - which showed the actual power consumption and energy efficiency of their existing compressed air systems - was therefore gathered from the ADA, and then analysed using the KESS in order to simulate system options. As a result, KAESER was able to present two configurations with an efficiency comparison. This information assisted Bright in selecting the right compressed air system design to efficiently meet their compressed air and budget requirements.
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Bright chose to keep their existing KAESER AIRCENTER 15 and to replace the ageing and inherited compressor with a new KAESER AIRCENTER 25. The AIRCENTER from KAESER is an all-in-one compressed air system, incorporating a high efficiency rotary screw compressor, refrigeration dryer and air receiver. At the heart of every compressor lies a premium quality KAESER rotary screw compressor block and energy saving SIGMA PROFILE rotors. Designed for maximum energy efficiency, the KAESER SIGMA PROFILE can achieve power savings of up to 15 percent compared to conventional screw compressor block rotor profiles. In addition, these compressors are equipped with a premium efficiency IE3 class drive motor which complies with and exceeds prevailing Australian GEMS regulations for 3 phase electric motors. For Bright this would translate into more
compressed air for less energy consumption. The result of undergoing the ADA and KESS for Bright was reduced energy costs and considerable environmental benefits. Burgess commented ‘With the recent developments to our business that are now taking us into new markets and increasing the depth of services we offer, it was important that we found a compressed air solution that would be able to meet our new requirements now and for the next 5 to 10 years. By undergoing the ADA and KESS with KAESER we were able to graphically and monetarily see – in terms of investment and energy costs - what the best options were. KAESER has always delivered the best solution to us, and we are certainly pleased with the final configuration which is already proving to be reliable in operation.’
Introducing the new MOBILAIR M235
Designed for continuous site operation under tough environmental conditions, the new MOBILAIR M235 diesel powered air compressor is the ideal solution for large portable compressor applications such as those found on mine sites. Part of the renowned MOBILAIR range of portable compressors that are manufactured at a state-of-the-art production facility in Germany, the new M235 dependably delivers the required compressed air at all times â€“ even under extreme conditions such as; at altitudes of 3000m above sea level or ambient temperatures up to 50oC. In addition, the powerful combination of the highly efficient KAESER SIGMA PROFILE rotary screw compressor block and an energy-saving 194 kW Cummins engine provides impressive performance and fuel efficiency. At the heart of every MOBILAIR portable compressor lies a high performance KAESER rotary screw compressor block equipped with the flow-optimised SIGMA PROFILE rotors. Designed for optimum energy efficiency, they can achieve power savings of up to 15 percent compared with conventional screw compressor block rotor profiles. Ideal for large portable compressor applications such as those found on mine sites, the M235 has been designed
to operate in tough conditions. The building site chassis with steerable axle and foldable tow bar, combined with the parking brake, ensures secure and space saving positioning of the compressor, as well as making it the ideal compressed air companion for no-road going areas. The MOBILAIR M235 has a generously dimensioned fuel tank. When filled, this ensures that there will be sufficient fuel for an entire work shift without the need for refuelling. For ease of operation, the fuel level can be seen at a glance via the analogue fuel gauge and an automatic shut-down feature is activated when the fuel level is too low. A pre-warning from the SIGMA CONTROL SMART controller provides additional peace of mind. All M235 portable compressors come with safety air filters as standard. Optimised design and separate air filters, including the safety element for the engine and compressor, considerably enhance reliability and service life. The filters can be changed on-site quickly and easily as required. The M235 is user- and service- friendly.
Equipped with a SIGMA CONTROL SMART controller, the compressor can be operated with just three buttons. In addition, the monitoring system can automatically shut the compressor down if necessary or report required maintenance. Service and maintenance can be carried out quickly and effectively, thereby ensuring maximum efficiency and compressed air availability. The MOBILAIR M235 is available with a certified spark arrestor for refinery applications. In addition, the engine shutoff valve automatically shuts down the unit upon intake of combustible gases to ensure maximum safety. It is also an ideal back-up air supply solution for industry and a skid mounted version is available where the M235 is required for a stationary application. Thanks to the availability of a wide range of optional compressed air treatment components, the M235 can deliver compressed air at the required quality at all times. Models are available in various pressure versions ranging from 8.6 to 14 bar, with free air deliveries from 18.1 to 23.3 m3/min. KAESER report | 15
Booster selected for PET blow moulding application
Quenching E'stel Water's thirst for high pressure compressed air technology
Growing product demand recently led premium alkaline water bottler E’stel Water to invest in a tailored and state-of-the-art KAESER compressed air system, complete with a turn-key DN series booster to meet the high compressed air pressure requirements of their new PET blow moulding machine. E’stel Water is a premium alkaline water that is sourced and bottled in Nelson. The artesian water comes from the snow-capped mountains of New Zealand and travels underground where it filters through various minerals. 895 metres below the surface of the Waimea Plains in Nelson, E’stel then extract this high alkaline water, before transporting it to a modern purpose built bottling plant, where it is; bottled, capped, labelled and packed ready for global distribution. The uniquely E’stel shaped plastic bottles
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that this high alkaline water is packaged in, are manufactured on site using a PET blow moulding machine. As demand for E’stel Water has steadily grown since the company was established just 3 years ago, so has the requirements of the bottling plant. This led to the recent investment into a much larger capacity PET blow moulding machine. Responsible for manufacturing the water bottles, the PET blow moulding machine relies on an efficient supply of compressed air.
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At certain points within the process, compressed air needs to be pressurised up to 40 bar. This inflates the soft PET (polyethylene terephthalate) plastic into a mold cavity which takes the desired shape and size of the water bottles. With a standard industrial compressor reaching around a 10 bar pressure, a booster compressor is therefore additionally required at those points in the production process where this high pressure compressed air is required, to literally boost, or increase, the air pressure up to the desired level of - in this case - 40 bar. The new PET blow moulding machine at E’stel is able to blow a staggering 11,000 bottles per hour (BPH). As it is a much larger system than what the company had previously, a new compressed air system was therefore required to meet this increased demand for compressed air. Wayne Herring, Co-Founder and Director of E’stel Water, called upon existing and local compressed air specialist – and authorised KAESER partner - PSL Total Air to present a suitable solution. In order to meet both the low and high pressure compressed air demand of the new PET blow moulding machine, PSL recommended and subsequently installed a complete compressed air system that included a KAESER CSD
105 rotary screw compressor and a KAESER DN 22 series booster.
the perfect high compressed air pressure solution for E’stel as Herring explains;
Unlike other boosters on the market, the KAESER DN 22 is a compact, plug and play turnkey package. These completely unique integrated booster systems are delivered and configured ex works to provide a system that is ready for immediate use.
‘We already had two standard pressure KAESER AIRCENTER compressed air systems being used for various other pneumatic applications within the facility, so we knew these compressors were reliable - something that is very important to our operation.
All DN series KAESER boosters are equipped with a premium efficiency IE3 class drive motors which complies with and exceed prevailing Australian GEMS regulations for 3 phase electric motors. Along with the generously dimensioned axial fan, which also assures reliable temperature control, this contributes to the booster’s cost effective energy usage.
When we started researching high pressure compressed air solutions, a lot of products on the market seemed to be manufactured using quite dated technologies, and the replacement of parts would have worked out to be very expensive.
For all round reliability, the DN series of boosters from KAESER also come with an integrated SIGMA CONTROL 2 controller as standard, which delivers efficient control and monitoring of the compressor operation. This greatly simplifies the diagnostics process for precision service and maintenance work. They can also be connected to a monitoring system, such as the SIGMA AIR MANAGER 4.0 master controller, allowing full integration into an Industrie 4.0 environment.
With the KAESER DN 22 booster we were presented with a cost effective and state-of-the-art packaged solution. PSL was able to tailor a compressed air supply system to meet our exact needs, and it is already proving to deliver an energy efficient and reliable supply of compressed air on demand. Their after sales service has also been fantastic.’ The DN series of boosters from KAESER are available with initial working pressures of 3 to 13 bar with final working pressure 10 to 45 bar, motor power 22 to 45 kW and free air deliveries 2.9 to 19.6 m3/min.
The KAESER DN 22 series booster was
'we were presented with a cost effective and state-ofthe-art packaged solution'
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Next generation filters
Energy saving Significant energy savings are possible with these next generation filters thanks to a number of design enhancements that have resulted in up to a 50 percent lower pressure loss compared to other filters on the market. The efficiency of a compressed air filter depends most of all on pressure loss. KAESER Filter products house a number of features which together deliver high filtering efficiency and minimal pressure loss;
confirmed by the independent ‘Lloyd’s Register’ testing agency. A service friendly design not only allows for simple and error-free opening and closing of the filter housing, but it also ensures quick and clean element changes.
The element head of the KAESER Filter units have been optimised for best possible air flow. Its tapered internal structure channels the compressed air to the centre of the element interior for even charging of the filter media. In addition, modern deep-pleated filter media is used in the KAESER filter range to remove particles and aerosols, while a highly effective carbon fibre mat traps oil vapours. Together with innovative flow dynamics, this ensures exceptional filtration efficiency with minimal pressure loss.
A practical bayonet lock ensures automatic positioning of the housing and element seals. Both seals are components of the filter element. This means that a filter housing can be sealed only if a filter element has been inserted. A locking screw prevents unintentional opening of the housing when under pressure and also provides housing venting.
Generously dimensioned connection flanges also assists in keeping pressure losses to a minimum. As KAESER filter products are available with air connection flanges of various sizes, there is no need for reducer sections when connecting to different air distribution networks. KAESER Filter products demonstrate a lower pressure drop right from the outset compared to other typically available filters on the market. Moreover, the pressure drop remains low for much longer thanks to the high contaminant retention capacity. The result is low life time operating costs. In addition, the annual maintenance of particulate and coalescence filters mitigates age-related risks and ensures maximum compressed air purity. Generously sized housings and filter surfaces, innovative flow dynamics and high performance filter media have all resulted in up to a 50 percent lower pressure loss in comparison to other filters on the market – a value that remains virtually constant throughout the entire service life of the filter element. This reduces the load on upstream compressors, thereby creating the potential for significant reductions in costs. As an example, just a 1 bar air
Fitted as standard to KAESER particulate and coalescence filters is a differential pressure gauge. This enables the user to monitor pressure losses – i.e. efficiency – at a glance. Unlike other commonly available systems on the market, the contaminated and clean air sides are isolated from one another.
pressure reduction can save up to 6 percent in compressed air associated energy costs. With this in mind it is possible to see how these intelligently engineered and generously sized filters can quickly pay for themselves by having a very low pressure differential. KAESER Filter products are dependable and efficient, characteristics that have been proven in the most sophisticated of testing environments and in stringent measurements programs. The impressive performance data of KAESER Filter products have been determined in accordance with ISO 12500 and
KAESER Filter product enclosures are cast from seawater-resistant aluminium. Several hundred hours of salt-spray testing have demonstrated their outstanding corrosion resistance. In addition KAESER filter elements are protected by inner and outer cages made from continuously welded profile stainless steel. These cages are far more resistant to mechanical stress than those made from simple expanded material. Manufactured to supply compressed air of all purity classes as per the ISO 85731 standard, KAESER Filter products are available in four high performance filter grades and 12 housing sizes, providing efficient filtration for flow rates from 0.6 to 32.0 m3/min. KAESER report | 19
KAESER COMPRESSORS Australia Pty. Ltd. Locked Bag 1406 - Dandenong South - VIC 3164 45 Zenith Road - Dandenong - VIC 3175 Phone: +61 3 9791 5999 - Fax: +61 3 9791 5733 www.kaeser.com.au - E-mail: email@example.com
KAESER COMPRESSORS NZ Limited PO BOX 301261 – Albany – Auckland 0752 18B Tarndale Grove – Albany – Auckland 0632 Phone: +64 9 941 0499 www.kaeser.co.nz - E-mail: firstname.lastname@example.org
New: MOBILAIR M 235 18.1 to 23.3 m3/min Efficient and durable Frost-proof protection
thanks to the compressed air aftercooler
thanks to the fold-up towbar and the powerful parking brake
with large enclosure doors providing easy access to the well-designed interior
Simple to operate
and exceptionally intuitive operation with the SIGMA CONTROL SMART controller
with fuel tank capacity sufficient for an entire work shift
screw compressor block featuring the energy-saving SIGMA PROFILE rotors
KAESER - More compressed air and more savings
Find out what's new at KAESER Compressors Australia and New Zealand