KAESER Report Australia 02/16

A Magazine for the Production Industry

2/16

Set in Concrete

Shotcreting in Auckland

Blown away

Industry 4.0 101

Along for the ride

e-power

Water Corporation: Treating waste water at the Collie WWTP

Industry 4.0-ready compressed air technology explained

Bringing three-dimensional shapes to life

Introducing the e-power range of electric portable compressors

Contents

Issue 2/16

3 Introduction

4-7

4

Blown away

Water Corporation: Treating wastewater at the Collie WWTP

8

Set in concrete

Concrete spraying with Shotcrete Auckland

12

Industry 4.0 101

Understanding Industry 4.0-ready compressed air technology

15 e-power

NEW: electric portable compressor range

16

Along for the ride

3DPrint-AU: Bringing three-dimensional shapes to life

8-11

18

Getting down to brass tacks

sshhmute practice mute

19

Knowledge is power

Training and education

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

16-17

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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Report 2/16

Peter Eckberg, Managing Director

Knowledge is power and knowledge can save you power ‘An investment in knowledge pays the best interest’ The industrial revolution – or Industry 1.0 – had just begun when Benjamin Franklin made this statement. Skip forward over 200 years and now as we enter a new era – Industry 4.0 - there is no doubt that his words are still as relevant today.

It is well documented that electricity prices have risen sharply over the past decade. Once seen as a relatively low fixed cost, energy has become an ever more important variable cost that impacts on company profits.

Often considered the fourth utility, compressed air is commonly one of the largest single energy consumers within a manufacturing facility and, depending on utilisation, electrical power can account for up to 90 percent of the total costs of compressed air production. In addition, the energy costs of a typical compressed air system can account for almost three quarters of its lifetime costs. It therefore makes sense to keep the power consumption of a compressed air system to a minimum.

Fortunately, compressed air is one source of energy

where significant and sustainable energy savings can be found and many existing compressed air users could be hiding an energy savings potential of 30 percent or more!

Anyone wanting to use compressed air energy efficiently must consider the compressed air system as a whole and understand the numerous correlations and interactions within the system and its integration into the operational environment.

The first step in realising such energy savings potential is therefore knowledge, and for many, compressed air training and education will be the key to unlocking this potential.

KAESER is committed to supporting the compressed air industry with training and education, and runs a number of seminars throughout the year designed to equip compressed air; end users, operators, supervisors and consultants, with the knowledge to assist them in optimising the productivity and energy efficiency of a compressed air system as well as controlling associated operating costs.

Knowledge really is power in optimising the energy efficiency of a compressed air system and consequently knowledge can save you power.

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Water Corporation: Treating wastewater at the Collie WWTP

Blown away Water Corporation supplies water, wastewater and drainage services to thousands of homes and businesses in Western Australia.

Wastewater management is an essential part of the water cycle and at present, the Water Corporation is responsible for the collection, treatment and either reuse or disposal of almost 450 million litres of wastewater a day!

When the wastewater reaches one of the many treatment plants (WWTP) that Water Corporation operates, it must go through a number of processes before it can be returned to the environment.

From aeration to digestion, a reliable and high quality supply of compressed air is required.

Recently, an inadequate process aeration system at the Collie WWTP was upgraded by the Water Corporation.

With a KAESER blower system already reliably powering the digestion process at the Collie WWTP, the local authorised KAESER Partner, Pneumatic Engineering was requested to propose a suitable blower system upgrade solution for the aeration process.

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Three KAESER EBC series blower systems were recently installed at Water Corporation’s Collie Wastewater Treatment Plant (WWTP) to efficiently and reliably meet the compressed air requirements of an upgraded process aeration system.

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To efficiently meet the demand for compressed air, Pneumatic Engineering recommended and subsequently supplied three KAESER COMPACT EBC series blower systems.

Part of the COMPACT series from KAESER, the EBC models have been designed to incur minimal operating and maintenance costs and to ensure maximum reliability; Every KAESER blower is equipped with a high efficiency blower block featuring OMEGA Profile rotors and an IE3 electric motor (which complies with and exceeds

The Water Corporation is responsible for the collection, treatment and either reuse or disposal of almost 450 million litres of wastewater a day!

6

prevailing Australian GEMS regulations for 3 phase electric motors) to ensure maximum energy savings and outstanding system performance. These highly reliable and robust OMEGA Blower blocks feature long life roller bearings and come pre-lubricated, ready for use.

In addition, a clever design not only delivers exceptional efficiency and dependability but also ensures a small footprint and ease of maintenance. An access friendly configuration enables side-by-side installation of multiple units, whilst a space saving component layout results in a very compact footprint.

The KAESER COMPACT series blower units are further delivered complete with an acoustic enclosure which has been designed

to minimise noise emissions.

The Water Corporation commented; ‘The blower systems have been up and running for over 12 months.

In that time they have proven to be exceptionally quiet in operation and very reliable in efficiently delivering compressed air as and when required.’ Together with their minimal maintenance and service requirements, these versatile blowers ensure lowest life cycle costs.

Mechanically tested in Germany, the KAESER BB-FB series rotary blower packages, are available with free air deliveries from 1.5 to 74 m3/min, pressure up to 1000 mbar, and vacuum to 500 mbar.

7

Set in

concrete

Concrete spraying with Shotcrete Auckland

8

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Shotcrete Auckland recently invested in a KAESER MOBILAIR 100 portable compressor, in order to generate a reliable supply of high quality compressed air required for the shotcrete process the company utilises in spraying concrete for its customers.

From architectural and landscape constructions to ground support, roads, bridges and dams; shotcrete is a versatile process used to lay concrete for numerous applications.

Shotcrete Auckland is the largest shotcrete firm in New Zealand and has over 30 years of experience in the field. The only company in New Zealand that is internationally certified by the American Shotcrete Association, Shotcrete Auckland recently invested in a KAESER MOBILAIR 100 portable compressor to assist in the reliable spraying of concrete using the shotcrete process.

Shotcrete is a versatile process able to lay concrete horizontally, vertically or even overhead.

Report 2/16

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The cement mixture is pumped through a hose and then pneumatically sprayed onto a surface. The velocity with which the cement leaves the nozzle allows for the concrete to be compacted at the same time.

Compressed air is an integral part of the shotcrete process, increasing the velocity at which the concrete leaves the nozzle.

A reliable supply of high quality air is essential to achieving a high shotcrete velocity and good compaction. This ensures denser concrete that will be less permeable and have a greater compressive strength.

Recognising the requirement for a reliable source of high quality compressed air, Glenn Tira, the Director of Shotcrete Auckland called upon their existing supplier Blueprint Diesel for a solution.

KAESER partner Blueprint Diesel recommended the KAESER MOBILAIR M 100 portable compressor to meet these requirements.

Shotcrete is a versatile process able to lay concrete horizontally, vertically or even overhead

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Part of the renowned MOBILAIR range of portable compressors from KAESER, the MOBILAIR 100 provides exceptional power and versatility.

Like all other portable compressors in the MOBILAIR range, the M 100 includes a KAESER rotary screw compressor block equipped with energy-saving SIGMA PROFILE rotors.

precision aligned roller-bearings this ensures long service life with maximum reliability.

In addition, MOBILAIR portable compressors are simple to operate, provide excellent component accessibility and are easy to maintain.

Shotcrete Auckland subsequently acquired an M 100. Glenn said;

‘Blueprint Diesel was great in finding the perfect compressor to meet our unique needs. We have been very impressed with the MOBILAIR 100.

It is doing exactly what we require!’

Manufactured at KAESER’s state-ofthe-art production facility located in Coburg, Germany, the MOBILAIR M 100 is available with a 71.7 kW drive motor, standard working pressures from 7 to 14 bar with free air deliveries from 6.4 to 10.2 m3/min.

All components found in the M 100 have been manufactured to the highest standards. Along with

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<blog> This blog post has been taken from the KAESER Australia Blog ‘KAESER Know How’. www.kaeserknowhow.com.au

Industry 4.0 ...and 4 ways you could benefit from Industry 4.0-ready compressed air technology

The way we manufacture is no doubt entering a new era led by the advances, networking and connectivity capabilities of production processes and technology. In this blog we look at what this new era - Industry 4.0 - is all about and the benefits to manufacturers of utilising Industry 4.0-ready compressed air technologies. Includes Industry 4.0 infographic.

What is Industry 4.0?

Many people believe that we are now entering a new industrial revolution Industry 4.0 or the fourth industrial revolution – where manufacturing is led by a number of cyber-physical systems.

Cyber-physical systems normally comprise of computers, networks and physical processes all integrated together.

Sending information back and forth, the computers and networks monitor and control the physical processes, with feedback from the physical processes also impacting the subsequent computations.

Using cyber-physical systems allows manufacturers to merge the physical world with the virtual world.

This is also sometimes called the Internet of Things (IoT) which describes how ‘things’ such as a piece of production equipment, is embedded with software, sensors

12 Report 2/16

and network connectivity, thereby allowing the physical object to collect and exchange data.

Put simply, “this means that industrial production machinery no longer simply ‘processes’ the product, but that the product communicates with the machinery to tell it exactly what to do.” (Germany Trade & Invest).

BCG has identified nine technological advances that form the building blocks of Industry 4.0; simulation, system integration, internet of things, cybersecurity, cloud computing, additive manufacturing, augmented reality, big data and analytics and autonomous robots.

Already used in manufacturing, it is the integration of these technological advances that will transform production. This means, that rather than various areas of a manufacturing plant working in isolation, through the implementation and integration of these nine technological advances, all production processes will also be

integrated together.

What does Industry 4.0-ready compressed air technology look like?

In the ultra-flexible Industry 4.0 production environment, intelligently networked compressed air systems provide the optimal compressed air power and quality required.

Moreover, potential issues within the compressed air network are identified at a very early stage so that appropriate service measures can be taken before a fault even occurs.

An advanced compressed air controller with secure networking abilities - such as the KAESER SIGMA AIR MANAGER 4.0 (SAM 4.0) - is a key technology in the advanced world of Industry 4.0.

As the central mastermind, it controls the entire compressed air supply system and – via IoT (Internet of Things) – it is responsible for

data streaming to a centralised application (in this case the KAESER SIGMA Smart Air application).

All compressed air system performance parameters are transferred from this sophisticated master control system to a data centre (the KAESER Data Center) in real-time via a powerful Ethernetbased network (the closed SIGMA Network). Here the parameters are analysed, processed, supplemented with expert knowledge and output to various mobile end devices (monitoring cockpits).

By monitoring key operating parameters, such as airend discharge temperature (ADT), pressure dew point or differential pressure, compressed air system efficiency can be kept in the optimum range at all times.

Thanks to real-time transmission and evaluation, data is always as up to date as possible, even in the event of sudden adjustments to production.

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Benefits of an Industry 4.0-ready compressed air system So, what are the benefits that manufacturers could enjoy by choosing to embrace Industry 4.0-ready compressed air technology?

1. Exceptional efficiency through continuous real-time monitoring and optimisation; real-time capture of all operational data and energy costs allows continuous energy efficiency optimisation of the entire compressed air supply. This helps to reduce the ongoing operating costs. Furthermore, the cost savings generated through this continuous optimisation process will ultimately benefit the bottom line.

2. Maximum availability through remote diagnostics, predictive maintenance and avoidance of critical situations; flexible demands on a compressed air supply system require flexible service. Conventional maintenance that relies on fixed maintenance intervals quickly reaches its limits. Networked predictive maintenance systems can help to avoid costly unscheduled downtimes and minimise maintenance and service costs by facilitating the planning process. Furthermore, dynamic maintenance

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reduces costs in accordance with actual demand.

With advanced compressed air technology, such as the SIGMA AIR MANAGER 4.0 master controller from KAESER, all operating and ambient parameters can constantly be delivered to a data centre in real-time (in this case the KAESER Data Center). Using specially programmed expert tools, irregularities can be detected at an early stage preventing costly downtime as a result.

3. Variable adjustment of compressed air control for individualised series production; real-time adjustment of the compressed air system to meet the air demand requirements of individualised series production requirements is possible with advanced and Industry 4.0-ready compressed air technologies.

4. Compressed air system management anywhere anytime; thanks to the networking and connectivity of advanced compressed air systems, it is possible to remotely visualise and manage a compressed air system from various mobile end devices â&#x20AC;&#x201C; anywhere and at anytime.

<infographic> For a detailed view of this infographic visit www.kaeserknowhow.com.au

NEW: electric portable compressor range

The new electric portable compressors from KAESER, are powered by motors rated at 15–25 kW, and form part of the highly successful family of MOBILAIR M27, M31 and M50 compressors.

From large building projects to city-centre sites or indoor operations – emission-free electricpowered portable compressors are exceptionally quiet and are significantly easier on the wallet than diesel units.

These machines are ideal for environmentally sensitive areas such as clean air zones or building sites near hospitals. They are also perfect for tunnel construction or as bridge

compressors for industrial stations.

On large construction projects, where power hook-ups are usually available, the electric compressors make even more sense, as electricity is generally much cheaper than diesel fuel. Another advantage: electric compressors cost far less to maintain.

Power consumption is kept to a minimum thanks to the inclusion of IE3 premium efficiency motors, which meet the IP55 enclosure and Class F insulation standards, as well as comply with and exceed prevailing Australian GEMS regulations for 3 phase electric motors.

The MOBILAIR electric portable

compressors are equipped as standard with the advanced SIGMA Control Smart controller and KAESER`s patented Anti-Frost Control.

The SIGMA Control Smart makes setup and operation – such as pressure adjustments – quick and simple with an easy-to-read colour display and the Anti-Frost Control protects tools from frost and corrosion.

The models are available with a choice of a rotational moulded polyethylene or metal enclosure and in both road-going and stationary versions. Flow rates range between 2 and 5 m³/min for pressures from 7 to 14 bar.

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3DPrint-AU: Bringing three-dimensional shapes to life

Along for the ride 3DPrint-AU recently invested in a KAESER SM9T rotary screw compressor to meet its requirement for a reliable supply of high quality and clean compressed air in its new dedicated 3D printing facility.

3D Printing Systems is Australiaâ&#x20AC;&#x2122;s leading distributor of 3D printers.

The company recently expanded its capabilities by opening its own dedicated 3D print services facility 3DPrint-AU that services consumer and business customers Australia wide.

3D printing, or additive manufacturing, is the process whereby a real object is created from a 3D design. Originally developed for rapid prototyping, 3D printing has become popular for the production of end use component parts.

Utilising Elite Selective Sintering (SLS) additive manufacturing 3D printers, 3DPrint-AU can print a range of products from; hobbiest models, smart phone cases and life critical orthopaedic surgical gloves, to strong and flexible functional nylon parts for industry that have highly complex designs, such as component parts for the automotive sector.

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The SLS printing process involves a laser being aimed into a bed of powder. The laser fuses (or sinters) the nylon powder, layer upon layer.

Once cooled, excess powder is then brushed off to reveal the threedimensional shape!

Compressed air is an integral part of the 3D printing process. The atmosphere in the printing chamber must be tightly controlled. This is achieved by using nitrogen as an inert gas, and this is produced by passing compressed air through a nitrogen generator. Crucially, the compressed air must be clean and dry, therefore free of water and oil vapour contaminants, which if present could cause product spoilage.

As a result a reliable supply of compressed air is a must in the 3D printing process, as Bruce Jackson, Managing Director at 3DPrint-AU explains: â&#x20AC;&#x2DC;If the compressor system were

to fail when we were printing it would deteriorate the quality of the end product. We cannot open the printer up mid-job, therefore we only find out if a print job has been successful once it has completed.

And, with a typical print job running continuously for 40 plus hours, you can understand why it was imperative that we sourced a reliable supply of compressed air!â&#x20AC;&#x2122; Having learnt that KAESER compressors were renowned for their reliability, in setting up the new 3D printing production facility in Auckland, 3DPrint-AU called upon authorised KAESER Compressors distributor Plummer Compressors to supply the compressed air system.

Plummers Compressor recommended and subsequently installed, a KAESER SM9T series rotary screw compressor with integrated refrigeration dryer, to reliably meet their demand for high quality compressed air.

The compact SM series rotary screw compressors from KAESER provide a reliable and energy efficient supply of compressed air to the smaller compressed air user.

premium efficiency IE3-rated drive motor (that complies with, and exceeds, prevailing Australian MEPS regulations for 3 phase electric motors).

At the heart of every SM series compressor lies a premium quality screw compressor block that features KAESER’s SIGMA PROFILE rotors. Designed to ensure maximum energy efficiency, the SIGMA PROFILE rotors can achieve power savings of up to 15 percent compared with conventional screw compressor block rotor profiles.

In addition, the SM T models include an integrated energy-saving refrigeration dryer. Linked to the operational status of the compressor, the refrigeration dryer automatically shuts down when the compressor is not in use for the ultimate energy saving solution.

Jackson concluded: ‘The KAESER compressed air system has proven to be reliable in operation. In fact we are so impressed with its performance that we are now recommending the

For maximum performance, reliability and efficiency, the screw compressor block is powered by a

KAESER equipment to our 3D printer customers.’

3DPrint-AU continues to rely on compressor specialist Plummer Compressors for its on-going compressor maintenance requirements.

Quiet, dependable and efficient, the KAESER SM series rotary screw compressors are available with integrated refrigeration dryer (SM T), with variable speed control (SM T SFC) or as a complete compressed air package; where both the compressor and refrigeration dryer are mounted on a compressed air receiver (AIRCENTER).

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Getti n

ssh

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te p r

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It’s a common problem often faced by brass instrument players; how to practice at odd times and in odd places with minimum noise and without changing the pitch or projection of the instrument.

Trevor Bremner, an Australian and New Zealand Cornet Champion and teacher had faced this problem himself many times. It was his

acti

ce m

n

ute

dissatisfaction with solutions currently on the market place that led him to invent the sshhmute Practice Mute.

Developed over several years, the sshhmute Practice Mute is now in full commercial production and has been successfully launched to answer a market need for an effective mute for brass instruments in a price range to suit budding musicians and professionals alike.

In the initial stages of production, the two parts of the sshhmute practice mute were bonded together manually with solvents. However now sold in over 33 countries, as demand has grown for the product, Bremner Music realised they needed to invest in a plastic welding machine to accelerate the production process.

A reliable supply of compressed air was required to power the new welding machine. Having heard that KAESER compressors were known for their German quality and high reliability, Trevor Bremner contacted his local authorised KAESER partner – PACE Power & Air for a solution.

PACE Power & Air worked closely

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with Bremner Music to spec up the correct compressor. They recommended and subsequently installed a KAESER CLASSIC 460 / 50 W. The KAESER CLASSIC series workshop compressors are designed and built to the strictest quality standards, yet are priced to meet the needs of small compressed air users without compromising efficiency, reliability and durability. The compressor block forms the heart of these units and is manufactured at KAESER’s main production facility in Coburg, Germany.

All KAESER CLASSIC compressors require minimal maintenance and are designed to provide years of efficient and reliable service.

Installed and operating now for almost 12 months, the KAESER CLASSIC compressor reliably powers the plastic welder that is used in the assembly of 5 out of the 8 sshhmute Practice Mute models.

Trevor Bremner said: ‘The KAESER compressor has proven to be a convenient ‘plug and play’ solution that is certainly living up to our expectations.’

Training and education

Knowledge is power KAESER has just launched a new series of Blower Technology Breakfast Seminars, ideal for consultants and end users alike who want to increase their understanding of the key blower technologies.

Planning a reliable, dependable and energy efficient blower system requires knowledge and understanding of the various blower technologies available, their advantages and disadvantages as well as their suitability to different applications.

In each case, a blower system that meets the very highest standards for reliability, quality and energy

efficiency, that above all else operates as cost effectively as possible, will be required.

With energy the largest operating cost to a wastewater treatment plant, selecting the right blower solution for each specific application is therefore paramount.

KAESER will be running a number of 90 minute Breakfast Blower

Seminars nationwide in the coming months.

If you want to increase your understanding about the blower technologies available and how to operate an energy efficient blower system then this seminar is for you!

For more information and to express your interest in attending a KAESER Breakfast Blower Seminar, visit www.kaeser.com.au

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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

KAESER COMPRESSORS NZ Limited PO BOX 301261 – Albany – Auckland 0752 18B Tarndale Grove – Albany – Auckland 0632 www.kaeser.co.nz - E-mail: info.newzealand@kaeser.com

Zero emissions

The new e-power portable compressors Sound enclosure

SIGMA CONTROL SMART

Made from rotation-sintered polyethylene, eye-catching and impact-resistant

Straightforward maintenance and easy pressure adjustment

IE3 electric motor Emission-free and efficient

Made in Germany

Exceptional build quality and durability

Rotary screw airend with SIGMA PROFILE More air, more savings...

e-power: quiet, efficient, emission-free