Cost Savings by Upgrading to Variable Speed Drive Technology

Last week, we wrote about a company that developed an energy efficiency program around its compressed air system and the amount the company saved just by right-sizing an off-peak compressed air system.

To determine energy usage in the manufacturing facility, the company brought in Atlas Copco to perform an MBox energy audit, which collected data over a seven day operating period. From the study, the company added a compressor that operates on the weekends, and with a rebate from the utility provider, the project paid for itself in three months.

About a year later, the plant experienced a failure of their main compressor. Because the compressor technology was outdated, it would be very costly to repair. So, the plant facility manager began looking for better options.

After running a second MBox energy audit, the variation in air demand throughout the production cycle suggested the need for a compressor with variable speed drive (VSD) technology. Variable speed drive technology adjusts the compressor’s operating speed in real time so production exactly matches demand. The energy audit also identified opportunities for energy recovery and was installed to cycle the waste heat from air compression through the closed loop hot water system that supplies building heat.

The results?

• Annual energy savings from new oil-injected, rotary screw VSD compressor: $5,676
• Annual building heating savings from Energy Recovery: $2,033

By upgrading the older technology to new, more efficient technology, the company will continue to see significant energy savings, resulting in a quicker return on investment.

Have you developed an energy efficiency program at your facility? Tell us about it in the comments below or contact us if you’d like to learn more about the MBox energy profile or Energy Recovery systems.