how an air audit brings down costs

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How an Air Audit Brings Down Manufacturing Costs?An Air Audit can pin point wastages in your Compressed Air System.

Compressed airsystems are usedextensively inTextile industry toprovide compressed

air for processes ranging from spinning,weaving, hosiery, dyeing etc. There are alsoseveral compressed air uses in industry thatin most cases can be considered misuses,which includes applications such as productcooling and cleaning.

It's about taking compressed air, lookingat it as your fourth utility, and making com-pressed air as dependable as your electric,water and gas services.

The challenges associated with operatinga modern compressed air system are fairlycomplex and often camouflaged to theuntrained eye. At the same time, many com-panies lack the internal resources trained todefine and solving those problems. That'swhere a professional Air Audit can help byaddressing the total process of producingcompressed air... not just the compressors.

Plant Air Audit: What's in it for you?

A well conducted audit of your com-pressed air system provides you with theonly sure way to bring down your com-pressed air related manufacturing costs andmanage the often mysterious workings ofyour air system.

Benefits of a CompressedAir System Audit

Audits provide the most accurate possi-ble data on the current system conditions tohelp manage the system identify component

upgrades and ensure the entiresystem operates as it should. Anaudit can help plant managementto:� Reduce compressed air costs

by 25% to 50%.� Reduce maintenance costs by

10% to 80%.� Get accurate data on current

system conditions andmachine health.

� Receive documentation onpower usage.

� Air Audit can be conductedwithout downtime or disrup-tion to productivity.

� Reduced capital spending� Improved manufacturing productivity

Air Quality for Textile Manufacturer

AirAudit can help you improve qualityand in turn improve quality of finished prod-ucts as air quality is a top priority for manymanufacturing processes, and in the textileindustry, clean, oil-free air often makes thedifference between usable end product andcontaminated waste.

Optimize Compressed Air System toTurn Off Compressors

Air Audits help plant operators optimizetheir systems and often result in turning offcompressors! This may sound crazy, but it'strue. In the past customers asked compressormanufacturers, like CompAir, to build thebest engineered, most reliable, energy effi-cient air compressors in the industry. But intoday's global business climate, you needmore than great equipment to survive andthrive. To drive operational excellence wemust go beyond the components of an airsystem and find solutions to the operatingissues every air consumer faces.

Compressed air system problems requiretotal solutions. A professionally conductedAir Audit help you define system problems,whether they are in demand, distribution orsupply, allowing you to develop cost efficientsolutions that meet your return on invest-ment goals.

Sustained health of thesystem requires

� Periodic Inspection.� Determining Compressed Air demand.

� Level of air quality.� Supply, storage, distribution manage-

ment.� Layout and installation consideration.� Ventilation.

Keeping Compressed Air Lines Dry

Compressed Air System are, traditionally,installed with water grade galvanized ironpiping and plumbing fittings, without takinginto consideration the host of design factorswhich effect its efficiency. GI Pipe loses itscoating where it is threaded, but this is thearea where rust proofing is most important.Thus, within three years, most systems arelosing up to 30% of compressed air throughleaks at the threaded joints. Furthermore,there is no leak inspection in most plants.Regular checkups are usually not performed,to discover leakages in piping as well as themachines using compressed air. The resultsare deteriorating performance over a periodof time. Air Audit highlights system failuresthat may otherwise not be detectable andmay silently be increasing yearly expenses onenergy.

An Air Audit helps large users of com-pressed air to identify opportunities forreducing energy consumption and overallbusiness costs. It provides benefit for the cus-tomers by evaluating the current runningsystem. The audit involves the evaluation ofthe leakages, corrosion in iron pipes, loosefitting of pneumatic pipes, machine damagedue to moisture and broken seals, etc. Textilemanufacturers, with air compressor loadsranging from 500KW to 2000KW can makehuge savings in electricity bills!

More details can be seen at www.airau-dit.com.pk �

Imtiaz Rastgar

Compressed Air Demand and Wastes.

PAKISTAN TEXTILE JOURNAL - July 2016