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High-tech compressed air for high-end products

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KAESER Compressors optimises compressed air system in a significant savings in energy costs

The customer of KAESER Kompressore SE manufacturers precision plastic parts for use in the automotive and medical technology sectors. The requirements for compressed air quality, which is used as control and process air, are very high in the medical sector in order to maintain the quality standard of the end products.

Challenge

The customer chose a contracting station from KAESER Kompressoren SE for this application in order to always be up to date with the compressed air supply and to be able to meet the requirements of Industry 4.0. In the case of contracting, the compressed air station itself remains the property of the manufacturer. The customer merely uses the compressed air like electricity from the socket. The amount of compressed air actually consumed is charged on the basis of a fixed price.

Solution statement

  • Installation of the KAESER compressed air station as a space-saving container variant on the company roof
  • Detailed compressed air audit as a basis for the design of a state-of-the-art KAESER compressed air station
  • The data obtained during the analysis was entered into the control system of the new plant – a KAESER Sigma Air Manager 4.0 (SAM 4.0) and forms the basis for highly efficient operation of the plant.
  • KAESER Control system simultaneously monitors the components as well as the ambient and production conditions.
  • The new KAESER compressed air station also made use of the possibility of heat recovery.

Customer value

  • High-quality, reliable compressed air supply, efficiency and energy cost savings
  • Easy to maintain
  • Networking and control in the sense of Industry 4.0 with the possibility of predictive maintenance
  • Optimization of the pressure quality as well as adjustment of the KAESER compressor station’s delivery rate in the event of fluctuating pressure consumption
  • Comprehensive optimization of energy efficiency based on control losses, switching losses, pressure flexibility
  • Control system offers the possibility of remote diagnostics
  • Reduction of oil consumption through the use of heat recovery

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