KAESER Report Australia 01/16

A Magazine for the Production Industry

1/16

6-9 July 2016, Melbourne

A date for your diary Mediquip breathes life into veterinary clinics

Katere blasts $10,000 per annum off its energy bill

Keeping the pendulums swinging

Dry-running compressors with i.HOC

KAESER Aircenter complements oxygen supply systems

More compressed air for less power consumption

Contributing partner at the 20th Biennale of Sydney

Introducing the NEW CSG-2 series

Contents

Issue 1/16

3 Introduction 4

Mediquip breathes life into veterinary clinics

KAESER Aircenter complements oxygen supply systems

6 Katere Coatings blast $10,000 per annum off its energy bill

4-5

6-7

More compressed air for less power consumption

8

Keeping the pendulums swinging

Contributing partner at the 20th Biennale of Sydney

10

KAESER at AWISA 2016

A date for your diary!

11 Dry-running compressors with integrated rotation dryer (i.HOC)

New: CSG-2 series

8-9 Publisher:

KAESER COMPRESSORS Australia Pty. Ltd. 45 Zenith Road, Dandenong, VIC 3175 Tel. +61 3 9791 5999 , Fax. +61 3 9791 5733 E-Mail. info.australia@kaeser.com, 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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Peter Eckberg, Managing Director

Networked thinking and action as prerequisites for Industry 4.0 success Industry 4.0 refers to the networking of machines and people via the Internet. It also involves the digitalisation, mirroring and processing of operational and machine data in highperformance databases, coupled with customerfocused applications. It represents an enormous opportunity to boost the productivity and efficiency of companies, which in turn will result in increased competitiveness.

However, before these prerequisites for Industry 4.0 can be implemented, the established structures, mindsets and approaches need to change. The fences marking out rigid organisational structures must be pulled down and, through project-based networking across all hierarchy levels, companies need to implement open communications extending to all departments and areas.

Knowledge and skills should be passed on, and indeed shared, without compromise. Mutual support increases each individual’s intellectual performance as well as that of the entire company.

Mixed teams that communicate effectively contribute a variety of perspectives, thereby boosting creativity and efficiency. Ultimately, this

form of networking yields benefits for everyone.

The result: a working environment shaped by collaborative thinking and activity that coalesces into a creative and flexible centre of cooperation.

The shared goal becomes a motivating factor driving the teams forward to complete their common tasks.

Cooperation must always transcend departmental boundaries with the goal of steering projects towards success while never losing sight of the company as a whole. This is the only way that the complex challenges posed by Industry 4.0 can be mastered. Additional attributes are also necessary, however, such as curiosity, a desire for life-long learning, a drive to do exceptional things and the ability to identify fully with shared objectives.

Change processes represent important challenges for management that must not only be understood, but also be subsequently implemented. Only in this way will Industry 4.0 culminate in the revolutionary success story that we anticipate it to become.

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KAESER and Mediquip breathes life into veterinary clinics Mediquip opts for the KAESER Aircenter to complement its oxygen supply systems which are assisting numerous veterinary clinics nationwide to efficiently and economically manufacture their oxygen requirements on site...

It is sometimes surprising when you stop and consider all of the places where compressed air is used. Typically we think about manufacturing, processing and engineering applications. However, compressed air serves a very important function in numerous other industry sectors, not least the veterinary industry where it is used to manufacture oxygen.

From small veterinary clinics to large animal hospitals, oxygen generation plays a key role in healing pets and animals. And, with one of the highest rates of pet ownership in the world and over 33 million pets, Australia certainly has a demand for the lifesaving services they provide!

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The traditional method of obtaining the oxygen would be to purchase it in cylinders. However, this method is costly and comes with the added inconvenience of having to move and change heavy and dangerous oxygen cylinders.

Mediquip, a biomedical and medical gas equipment sales and service company, offers the Australian veterinary industry with a highly economical, convenient, safe and compact alternative - oxygen supply plants. Powered by a compressor, an oxygen supply plant generates near pure oxygen from the air we breathe by using a method called pressure swing adsorption. Air is forced under pressure by a compressor into a

cylinder. The cylinder contains a material that effectively separates the oxygen from the other gases in the air.

Once the material has adsorbed these gases, a valve is opened for the almost pure oxygen to exit into a holding reservoir. An exhaust valve is then opened, allowing the other gases to escape. This system employs two cylinders running in opposite cycles to produce a continuous flow of oxygen.

Mediquip has over 30 years of experience in providing biomedical and medical gas solutions to the Australian healthcare, aged care, emergency and veterinary industries.

The company chose to partner with KAESER to present a complete oxygen supply plant solution to its customers several years ago, as Kurt Hogan, General Manager at Mediquip explains; ‘KAESER was originally recommended to us by a supplier in America that was already successfully installing the oxygen supply plants with KAESER compressors. With a reputation for manufacturing German made and top quality compressors and accessibility to nationwide service support, KAESER was the right choice to complement our oxygen supply systems.’

The oxygen supply plants from Mediquip come with a KAESER Aircenter; a complete and compact turn-key system for the production of dry compressed air, which incorporates a compressor, dryer and air receiver all within a single housing.

At the heart of each Aircenter lies a proven KAESER rotary screw compressor featuring a premium quality screw compressor block with KAESER Sigma Profile rotors that have been designed for maximum energy efficiency.

The inclusion of a thermally shielded refrigeration dryer further ensures a dependable supply of

dry and clean air - a feature that was key in Mediquip’s decision in selecting the KAESER Aircenter for this application as Hogan explains; ‘The air must be clean to adhere to the same quality standards expected of breathing air and as the oxygen generation process uses a material molecular structure which is susceptible to moisture and contaminants, choosing a compressor from a manufacturer that we could trust to meet these high quality air standards was paramount.’

allowing us to make our own oxygen as and when required. Compactly installed the system generates the oxygen we need on demand which is then available via a piping system in all of our surgery rooms.’

The RSPCA Victoria’s veterinary clinic in Burwood East is one customer that has realised the benefits of the Mediquip oxygen supply plant. Providing care to animals seven days a week, 365 days a year, oxygen needs to be readily available at the clinic for a number of uses including the anaesthetic machines and humidicribs used in intensive care.

Andrew Byrne, Chief Veterinarian at the RSPCA Victoria said; ‘We were previously obtaining the oxygen we required in cylinders.

This was proving to be costly and required a lot of attention to ensure that we always had enough oxygen on hand. The oxygen supply plant from Mediquip solved these issues,

Above: The oxygen supply plant at the RSPCA Victoria’s veterinary clinic in Burwood East

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Blast off Katere Coatings blast $10,000 per annum off its energy bill KAESER Compressors has assisted Katere Coatings in creating energy savings in excess of $10,000 (AUD) per annum. This significant saving has been realised through investing in two KAESER rotary screw compressors, designed and manufactured to deliver more compressed air for less power consumption.

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New Zealand based Katere Coatings is a family operated business that has been providing its customers with high quality industrial plant and equipment cleaning solutions, as well as protective and restoration coatings, for over 20 years.

An ageing and increasingly unreliable and inefficient compressed air system led Kris Vinsen, the Director of Katere Coatings to invite his service partner - and the local authorised KAESER partner - PACE Power & Air, to suggest a solution.

To ensure fast turn-arounds and a high quality finish, Katere Coatings relies not only on its highly skilled team but also well-maintained and up-to-date equipment.

Having already performed a KAESER Air Demand Analysis (ADA) on the compressed air system, PACE Power & Air had been able to identify that there were two fairly consistent volumes of air usage.

The most efficient system solution was therefore to install two different sized compressors, recommending and subsequently installing a KAESER ASD 50 T and a BSD 83 T rotary screw compressor, both with integrated refrigeration dryers.

Compressed air is used extensively in both abrasive blasting and painting. A dry and clean supply of reliable compressed air is essential in both ensuring an even blast finish and a smooth paint finish.

The ASD T and BSD T series of rotary screw compressors with refrigeration dryers both save energy in multiple ways: At the heart of every KAESER rotary screw compressor lies a premium quality screw compressor block which features KAESER’s Sigma Profile rotors. Developed by KAESER and continuously enhanced ever since, the KAESER Sigma Profile achieves power savings of up to 15 percent compared with conventional screw compressor block rotor profiles.

Both models are controlled and monitored by the industrial PCbased Sigma Control 2 compressor controller. This enables free air delivery to be precisely matched to meet actual compressed air demand and together with Dynamic Control effectively minimises costly idling periods for maximum energy efficiency.

The integrated refrigeration dryers in these units also provide high efficiency performance thanks to energy saving control. Because the dryer is active only when compressed air actually needs to be dried, the required compressed air quality is achieved with maximum efficiency.

On installation, PACE Power & Air set up a ‘lead and lag’ configuration which allows for the ASD 50 T to provide the day to day compressed air required. When the demand picks up the BSD 83 T will then kick in to provide the extra demand. This configuration delivers a far more efficient solution to Katere Coatings than if they had opted for just one larger compressor.

Every KAESER rotary screw compressor quickly pays for itself through significant savings in energy costs. In this instance, Katere Coatings managed to blast over $10,000 (AUD) per annum off its energy bill! Kris Vinsen commented; ‘The efficiency of our compressed air supply has increased since we installed the KAESER compressors which reflects in the energy savings we are enjoying off our utility bills!

The improvement in reliability is also considerably noticeable.’

Left: Compressed air is used extensively at Katere Coatings in both abrasive blasting and painting

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Keeping the

pendulums swinging

A KAESER SK 25 T rotary screw compressor with integrated refrigeration dryer is supplying the power behind renowned choreographer William Forsythe’s art installation ‘Nowhere and Everywhere at the Same Time Nr.2’, featuring at the 20th Biennale of Sydney.

Widely considered one of the world’s foremost choreographers, William Forsythe is recognised for deconstructing and reorienting the practice of ballet, with works which have moved beyond any

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identification with a classical repertoire, to a dynamic art form for the twenty-first century.

Alongside and in dialogue with his choreographic work, Forsythe has

also developed a diverse practice incorporating elaborate architectural, multimedia and performance installations. This includes the choreographic object, Nowhere and Everywhere at the Same Time which

has featured around the world in a number of art museums and at a number of art festivals.

Originally created for a solo dancer and 40 pendulums in an abandoned building in New York, the installation has been continuously developed in contexts as diverse as the monumental industrial architecture of the Turbine Hall of the Tate Modern to the historical setting provided by the Arsenal of the Venice Biennale.

Suspended from automated grids, the installation now includes 300 pendulums which are activated to initiate a sweeping 16 part counterpoint of tempi, spacial juxtaposition and gradients of centrifugal force which offers the spectator a constantly morphing labyrinth of significant complexity.

Spectators are invited to avoid coming into contact with the swinging pendulums whilst they navigate this unpredictable environment.

The suspended pendulums are activated by pneumatics which are powered by compressed air. Since conception through to the execution of each installation, the Forsythe Company has opted for a KAESER SK 25 T rotary screw compressor with integrated refrigeration dryer to power this installation.

Compressed air users expect maximum availability and efficiency - even from smaller compressors.

The SK series of rotary screw compressors from KAESER go far beyond meeting these key expectations. Not only do they deliver more compressed air for less power consumption, but they also combine ease of use and maintenance with exceptional versatility and environmentally responsible design.

At the heart of every SK series

system lies a premium quality compressor block featuring KAESER’s Sigma Profile rotors.

Developed by KAESER, the Sigma Profile achieves power savings of up to 15 percent compared with conventional screw compressor block rotor profiles for a highly energy efficient solution.

In addition, all KAESER rotary screw compressor blocks are powered by premium efficiency IE3-rated drive motors (that comply with, and exceed, prevailing Australian MEPS regulations for 3 phase electric motors), for maximum performance and reliability.

The SK T models include an integrated refrigeration dryer.

Installed in a separate enclosure to shield it from heat radiated by the compressor; this design approach enhances reliability. An automatic dryer shutdown feature further aids energy-efficient performance.

All SK series models share logical and user-friendly design throughout, with all maintenance work able to be carried out from one side of the unit for ease of use and service.

These have become key reasons why the Forsythe Company has continued to opt for a KAESER compressor each time this installation has been exhibited. As Julian Gabriel Richter, Director of Production commented: ‘We used a KAESER compressor for the initial try-outs of this project. It functioned without any problems and was easy to use. As a result we have opted for a KAESER compressor each and every installation of this choreographic object.

This has proven to be a successful configuration for us; we have never had any problems with the KAESER compressors we have used, they are

William Forsythe

Nowhere and Everywhere at the Same Time Nr.2, Cockatoo Island

fast to service and, they are available worldwide.’

Part of the 20th Biennale of Sydney, William Forsythe’s installation is open to the public from 18 March to 5 June 2016 within the Precinct of Cockatoo Island in Sydney, of which KAESER is proud to be a contributing partner.

A non-profit organisation that presents Australia’s largest and most exciting contemporary visual arts festival, the Biennale of Sydney is a three-month exhibition held every two years, which has showcased the work of nearly 1,700 artists from over 100 countries at venues across Sydney since 1973.

Photographs: Dominik Mentzos / Biennale of Sydney. All courtesy the artist.

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6-9 July 2016, Melbourne The Woodworking Exhibition 2016

A date for your diary KAESER will be exhibiting at AWISA 2016 being held at the Melbourne Exhibition Centre from 6 to 9 July 2016. Visitors to stand number 909 will be able to discover a comprehensive range of compressed air solutions for the woodworking industry, not least the compact and complete Aircenter a turn-key compressed air system that combines a rotary screw compressor, refrigeration dryer and air receiver - all in one package.

Visit KAESER on stand number 909 10 Report 1/16 - www.kaeser.com.au

Dry-running compressors with integrated rotation dryer (i.HOC)

New: CSG-2 series The two-stage, dry-running compressor airend guarantees consistently high efficiency throughout its entire service life.

Temperature-resistant up to 300°C, the smooth “Ultra Coat” coating on the rotary screw rotors is exceptionally wear resistant and maintains its sealing and protective properties to ensure consistent compressed air delivery and energy efficiency even after many years of use. The air-cooled versions provide dependable performance for ambient temperatures up to +45°C. The second compression stage uses stainless steel rotors to further safeguard compressed air quality and extend service life. Fibrefree pulse dampers assure minimal pressure loss and dependable compressed air quality.

Based on industrial PC technology, the integrated Sigma Control 2 compressor controller allows users to benefit from maximum efficiency and dependability and also provides compatibility with future innovations (Industry 4.0). Its variable interfaces and plug-in communications modules enable rapid and secure networking with master compressed air management systems (SAM), computer networks and operations control systems. The RFID reader helps standardise service and provides exceptional security.

Air- and water-cooled CSG-2 series

compressors are both equipped with energy-saving IE4 Super Premium Efficiency motors. The already low power consumption values can be reduced even further in combination with additional efficiency optimisation features. Low compressed air discharge temperatures are easily achieved without any additional hardware thanks to the integrated compressed air aftercooler, which operates with minimal pressure loss. Furthermore, KAESER hot air control is available on CSG-2 units for applications requiring hot compressed air, such as jet mills.

CSG-2 compressors are compact units with integrated compressed air dryers, so they’re perfect for delivering clean and dry compressed air when and wherever needed.

Users can choose between the revolutionary i.HOC rotation dryer and a highly advanced refrigeration dryer. i.HOC dryers are specially designed for use with KAESER’s dry-running compressors and are precisely matched to the specific compressor they’re paired

with. They deliver dry compressed air down to a pressure dew point of -30°C – right from the very first revolution. Since they use heat from the compression process to regenerate the desiccant, no additional energy is required to power the drying process, which results in maximum efficiency and lower energy costs. When pressure dew points of only +3°C are required from the compressor/ dryer combination (as is the case for the majority of applications), CSG-2 units are available upon request with a ready-integrated refrigeration dryer. Compressed air refrigeration dryers from KAESER feature proven designs and ensure outstanding reliability. The CSG-2 and refrigeration dryer combination is especially interesting for applications where maximum availability of appropriately treated compressed air is required and space is at a premium – significantly less space is needed compared to a compressor paired with an external refrigeration dryer.

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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: info.australia@kaeser.com

Efficiency and performance The new M350 portable compressor SIGMA CONTROL SMART

Straightforward maintenance and easy pressure adjustment

User friendly design

Simple to operate, providing excellent component accessibility for ease of maintenance

Rotary screw airend with SIGMA PROFILE

Made in Germany

Exceptional build quality and durability

Mobilair: Compact, energy efficient

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More air, more savings...