Cement Two-Stage Compressors Energy Star

Transcription

1 Cement Two-Stage Comressors Energy Star N o v e m b e r / D e c e m b e r TM

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3 Focus Industry MANUFACTURING / 0 6 COMPRESSED AIR BEST PRACTICES FOCUS INDUSTRY FEATURES Promoting Energy Efficiency in Cement Making: 8 The ENERGY STAR for Industry Program By Ernst Worrell and Eric Masanet Managing Dust Collectors in Cement Production 15 By Hank Van Ormer 39 PRODUCT & SERVICE FEATURES Two-Stage Rotary Screw Air Comressors 35 By Harish Shah and Mark Pfeifer Manufacturing: Auto-Surveillance Adds 39 Efficiency to Vacuum Alications By Bob Buerkel

4 COMPRESSED AIR BEST PRACTICES / 0 6 Focus Industry MANUFACTURING Comressed Air Best Practices JOB MARKET ADVERTISING RATES MAGAZINE ADS For smaller classified-tye ads use the following rates er column inch: 1x er year: $94.00* er column inch 3x er year: $90.00* (i.e., this is a 10 col. inch, reversed ad) 12x er year: $84.00* *reversed ads = 1.5x normal rice Add $50.00 to ost the job oening on when you urchase an ad in the magazine Contact Patricia Smith for 4 color full age, 1/2 age and 1/3 age ad rates ONLINE ONLY ADS Each job osting is u on the site for 60 days. Postings can be urchased in bulk quantities er the rates below. The customer has twelve months to ut the ostings on the site. After twelve months, any unused ostings will be charged at the minimum quantity. Small Price Per Bulk Price Per Qty. Posting Qty. Posting 1 $ $ atricia@airbestractices.com, tel:

5 Comressed Air Industry MANUFACTURING / 0 6 COMPRESSED AIR BEST PRACTICES COMPRESSED AIR INDUSTRY ARTICLES From the Editor 7 Sullair Cororation 19 Scales Industrial Technologies 24 BEKO Technologies 29 Industrial Marketing 43 Job Market

6 COMPRESSED AIR BEST PRACTICES / 0 6 SUBSCRIBE NOW! Focus Industry MANUFACTURING COMPRESSED AIR BEST PRACTICES MAGAZINE Advertising & Editorial: Rod Smith rod@airbestractices.com Tel: COMING EDITIONS! IDEAL GIFT FOR EMPLOYEES Subscritions & Administration: Patricia Smith atricia@airbestractices.com Tel: IDEAL FOR: INDUSTRY: Plant Engineers, Plant Managers & Maintenance Managers MANUFACTURERS: Management, Sales, Marketing & Engineering COMPRESSOR DISTRIBUTORS: Every Branch Location Rates: 12-month Subscrition Number of Subscritions U.S. $55.00 $50.00 $45.00 $40.00 Canada $65.00 $60.00 $55.00 $50.00 International $95.00 $90.00 $85.00 $80.00 A Publication of: Smith Onandia Communications L.L.C. 161 Clubhouse Circle Fairhoe, AL COMING NEXT MONTH! Bio-Methane Lubricants Flow Meters J A N U A R Y TM 3 WAYS TO SUBSCRIBE: * 1.) Call Patricia Smith at and use your VISA/Mastercard. 2.) us at atricia@airbestractices.com and mail your check. 3.) Mail your information and check to: Comressed Air Best Practices 161 Clubhouse Circle Fairhoe,AL Checks should be made out to Smith Onandia Communications, LLC. Questions, call Patricia Smith: *Information required: First Name: Last Name: Comany Name: Street: City: State (Province): Country: Phone: Fax: Zi Code: Comressed Air Best Practices is ublished monthly by Smith Onandia Communications LLC., 161 Clubhouse Circle, Fairhoe, AL, Phone (251) Publisher can not be held liable for non delivery due to circumstances beyond its control. No refunds. SUBSCRIPTIONS & REPRINTS: Annual rates for one subscrition: U.S. $55; Canada $65; International $95. Rerints are available on a custom basis. Contact Patricia Smith for multile-subscrition discounts, rerint quotations and customer service at (251) or atricia@airbestractices.com. When available, extra coies of current issues are $20. Standard ostage aid at 233 Jefferson Street, Greenfield Ohio Canadian and international distribution: IMEX International Mail Esress, 1842 Brummel Drive, Elk Grove Village IL POSTMASTER: Send address changes to Comressed Air Best Practices, 161 Clubhouse Circle, Fairhoe, AL Printed in U.S.A. 6

7 Focus Industry MANUFACTURING COMPRESSED AIR / 0 6 BEST PRACTICES FROM THE EDITOR Placing The Customer First Have you ever worked for a comany obsessed with dominating the market they are in? If you are ambitious and haven t met u with one what are you waiting for? Small and large, rivate and ublic, I meet many comanies whose emloyees are assionate about dominating their industry.the only common denominator I have seen in these comanies is that ALL emloyees are obsessed with serving customers. Some say that only rivate comanies have the assion for organic growth any more.there is nothing like the scenario of an extremely cometent owner of a firm leading the charge.the emloyees are taught the business of business and also the business of life. I had the rivilege of working for this tye of comany and I think I learned just as much about how to live my life as I did about business. Comensation was a minor consideration. Often these businesses create an extended family of highly skilled and loyal rofessionals, who dominate the business they focus on.we have two such examles in this month s edition, Scales Industrial Technologies and BEKO Technologies. Mr. Bill Scales, the CEO of Scales Industrial Technologies, shares with us their unique organization chart, which laces customers at the to and management at the bottom. Mr. Berthold Koch, Chairman of BEKO Technologies, demonstrates how a comany can grow by designing roducts that customers are asking for. Some say that only big ublic comanies have the resources to dominate an industry. Others say that ublic comanies just want to rotect their stock rices.there are large cororations who make acquisitions and then make the new divisions more rofitable by rationalizing and consolidating lants and roduct lines. Customers don t usually win. Other cororations make acquisitions and immediately invest in the new division.they invest in things customers can benefit from exanded roduct lines, quality systems, exanded sales & marketing, imroved lead times, better customer service. In this month s edition, Sullair Cororation a division of United Technologies Cororation, discusses the ositive results their Voice of the Customer new roduct develoment rograms have given them. In order to dominate an industry, countless things are required. Placing the customer first in your organization chart is a good lace to start.actually dedicating your time, energy, and talents, towards taking care of customers will determine your results. your name here Time to reinforce your brand? Why not lace your most valuable asset right where your customers will see it, on the roducts themselves. Walker Filtration technology and volume based design, manufacturing & branding exertise can hel. The ultimate filtration & drying technology For more information lease contact our sales deartment on: tel fax info@walkerfiltration.com ROD SMITH Walker Filtration Inc, 2220 West 50th Street, Erie, PA 16506, USA 7

8 COMPRESSED AIR BEST PRACTICES / 0 6 Focus Industry MANUFACTURING PROMOTING ENERGY EFFICIENCY IN CEMENT MAKING: THE ENERGY STAR FOR INDUSTRY PROGRAM BY ERNST WORRELL AND ERIC MASANET, LAWRENCE BERKELEY NATIONAL LABORATORY The ENERGY STAR for Industry Program As U.S. manufacturers face an increasingly cometitive global business environment, they seek oortunities to reduce roduction costs without negatively affecting roduct yield or quality. Uncertain energy rices in today s marketlace negatively affect redictable earnings, while increasing energy rices are driving u costs and decreasing their value added. Energy efficiency can be an effective strategy to work towards the so-called trile bottom line that focuses on the social, economic, and environmental asects of a business. In short, energy efficiency investment is a sound business strategy in today s manufacturing environment. ENERGY STAR is a voluntary government rogram that offers businesses and consumers a broad range of resources on the best in energy efficiency to hel save money and rotect the environment.the ENERGY STAR for Industry Program works directly with U.S. manufacturers to hel them imrove cometitiveness through imroved energy management, increased energy efficiency, and reduced environmental imact. ENERGY STAR s website rovides more information on the rogram and oortunities to articiate (see To date, the ENERGY STAR for Industry rogram has established eight different Industrial Focuses in artnershi with secific energy-intensive industries in the United States. Current and ast Industrial Focuses include motor vehicle manufacturing, corn refining, cement manufacturing, breweries, etroleum refining, glass manufacturing, harmaceutical manufacturing, and food rocessing. Many of the comanies articiating in these Industrial Focuses have reorted significant cost and energy savings and have gone on to receive recognition as leaders in energy efficiency and environmental erformance.the cement industry was one of the first sectors to actively articiate in an ENERGY STAR Industrial Focus, and many of today s U.S. cement comanies articiate in the rogram. As art of each Industrial Focus, articiating comanies have access to energy rofessionals who offer assistance to lant energy managers and share roven, non-rorietary aroaches for imroving cororate energy management. An annual Industrial Focus forum is also held, where comanies can oenly discuss non-confidential issues confronting their energy management rograms. ENERGY STAR also offers each Industrial Focus two key management tools for imroving lant-level energy erformance: (1) the lant Energy Performance Indicator (EPI), which is a software tool that allows individual lants to benchmark their energy erformance against industry eers using data from the U.S. Census Bureau, and (2) the Energy Guide, which discusses a wide variety of energy efficiency oortunities alicable to lants within the focus industry, including information on best ractices for comressed air system efficiency. 8

9 Get Good Air. Get AirMetrix ṢM Maximize the Productivity of Your Comressed Air System Use Sullair s AirMetrix SM rogram to take a Systems Aroach to comressed air, and watch your costs dro while erformance rises. AirMetrix SM begins with a review of your current and future air needs using audit tools that address the Deartment of Energy s air system auditing standards. We analyze the design and erformance of your air system s comonents on both the suly and demand side. We ll find the inefficiencies, like unnecessary ressure dros, leaks, or system design shortcomings that run your comressors too hard. Your solution can be as simle as adding storage tanks or flow controllers to your current system. And, of course, Sullair s AirMetrix SM also gives you a single source for comressor fluids, arts, and system accessories. Look to Sullair for a comlete range of some of the most reliable, efficient, and serviceable industrial air comressors in the world. We can also add sohisticated system monitoring tools like econnect to hel you monitor and control your comressors from anywhere in the world... or, comletely outsource your air needs with the most comlete AirMetrix SM solution of all AirTility. To learn more about AirMetrix, SM visit Or call us at: SULLAIR or

10 COMPRESSED AIR BEST PRACTICES / 0 6 THE ENERGY STAR FOR INDUSTRY PROGRAM Focus Industry MANUFACTURING Box 1: The Energy Guide for Cement Plants The Energy Guide, which is titled Energy Efficiency Imrovement and Cost Saving Oortunities for the Cement Industry: An ENERGY STAR Guide for Energy and Plant Managers, was released by the U.S. EPA in The Energy Guide is designed to reduce information barriers by roviding lant and energy managers with a concise source of state-of-the art information on energy efficiency measures alicable to their lants. The Energy Guide contains detailed information on over 40 energy efficient technologies and energy management ractices alicable to the cement lants in the following categories: Energy management rograms and systems Motor systems Comressed air systems Kilns Grinding (both raw materials and finish grinding) Product changes (e.g. blending, limestone addition) Emerging technologies The Energy Guides are researched and authored by Lawrence Berkeley National Laboratory (LBNL) in artnershi with ENERGY STAR and articiating focus comanies.the Energy Guides are used by energy managers to identify areas for energy efficiency imrovements, to evaluate otential energy imrovement otions, to develo action lans and checklists for lant-level energy management, and to educate comany emloyees on the imortance of and actions for imroved energy efficiency. LBNL develoed an Energy Guide for the cement industry as art of the ENERGY STAR Industrial Focus on cement making. This Energy Guide contains an overview of industry trends and energy use as well as detailed information on a large number of energy efficient technologies and energy management ractices alicable to a cement lant (see Box 1). This article rovides a brief summary of information contained in the Energy Guide. The U.S. Cement Industry After China and India, the U.S. cement industry is the largest in the world roducing 99 Million metric tons (Mt) of cement in Cement is roduced in two stes. First clinker is made by burning a mixture of raw materials (mainly limestone). The clinker is then ground and mixed with other materials (e.g. gysum, limestone or additives such as fly ash or blast furnace slag) to make cement.the industry is made u of integrated lants that roduce clinker and grind it to make finished cement, and cement lants that grind urchased clinker and additives. In the U.S., there are currently no standalone clinker lants.there were 115 oerating cement lants in the U.S. in 1999, sread across 37 states and Puerto Rico. The to-10 leading comanies roduced over 80% of the cement in the U.S. Cement comanies in the U.S. roduced $8 Billion of cement, while the cement market in the U.S. reresents a value of $10 Billion.The majority of U.S. cement caacity is owned by multinational comanies. Production rates er lant vary between 0.5 and 3.1 Mt er year. Clinker and cement roduction exerienced gradual growth since the 1970s, with rominent dis in the late 1970s and early 1980s (see Fig. 1).Within this slow roduction increase, the comosition of clinker roduction changed significantly since1970. Clinker roduced with the energy-intensive wet rocess decreased from a 60% share of total clinker roduction in 1970 to a 16% share in Clinker roduced with the dry rocess increased from a 40% share of total clinker roduction in 1970 to a 78% share in 2004, with the remaining 6% not classified as wet or dry rocess. Cement roduction increased from 69 Mt in 1970 to 99 Mt in Cement roduction grew more raidly (1% average er year) than clinker roduction (0.8% average er year) between 1970 and 2004, due to increased use of additives and increased clinker imorts. Figure 1. Clinker and Cement Production in the United States from 1970 until

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12 COMPRESSED AIR BEST PRACTICES / 0 6 THE ENERGY STAR PROGRAM Energy Use FOR INDUSTRY Focus Industry MANUFACTURING SUBSCRIBE NOW! The cement industry is one of the most energy intensive industries, with energy reresenting 30 40% of roduction costs. In 2004, the U.S. cement industry consumed 531 TBtu of rimary energy. Energy consumtion in the U.S. cement industry declined between 1970 and Primary energy use decreased at an average of 0.3% er year, from 556 TBtu in 1970 to 531 TBtu in 2004, although roduction increased over that time san. Since the 1980s the use of waste derived fuels is growing in the cement industry. By 2004 over 12% of all fuels were waste derived fuels, e.g. tires, solid and liquid wastes (solvents), which is low comared to some Euroean countries. The trend towards increased use of waste derived fuels will likely increase. While fuel is the main energy inut in the cement making rocess, electricity use is still considerable. In 2004, the cement industry consumed nearly 14 TWh of electricity (or 11% of total energy inuts, on a final energy basis). Electricity use is a considerable cost exceeding $617 Million er year. On average the U.S. cement industry consumes 142 kwh/metric ton of cement. The major end uses of electricity in the industry are summarized in Figure 2. Electricity is mainly used for drives, of which the motors used in grinding rocesses and kiln drives are the key energy uses. Combined all drives consume about 80% of all electricity. Of the drive systems, comressed air is a relatively small end use, estimated at about 6% of the industry s electricity use, or nearly 850 GWh (equivalent to an estimated cost of over $40 Million/year, or enough to ower 80,000 U.S. households). Comressed air is used in many arts of the lant for many uses including silo control, on-site transort of raw materials to the kiln, baghouse collector filters, air knives, dedusting and, esecially, in wet rocess clinker lants in the mixing of raw materials to reare a slurry that is fed to the kiln. Figure 2. Estimated Breakdown of Electricity Use in the U.S. Cement Industry, 2002 COMING EDITIONS! IDEAL GIFT FOR EMPLOYEES IDEAL FOR: INDUSTRY: Plant Engineers, Plant Managers & Maintenance Managers MANUFACTURERS: Management, Sales, Marketing & Engineering COMPRESSOR DISTRIBUTORS: Every Branch Location Rates: 12-month Subscrition Number of Subscritions U.S. $55.00 $50.00 $45.00 $40.00 Canada $65.00 $60.00 $55.00 $50.00 International $95.00 $90.00 $85.00 $ WAYS TO SUBSCRIBE: * 1.) Call Patricia Smith at and use your VISA/Mastercard. 2.) us at atricia@airbestractices.com and mail your check. 3.) Mail your information and check to: Comressed Air Best Practices 161 Clubhouse Circle Fairhoe,AL Checks should be made out to Smith Onandia Communications, LLC. Questions, call Patricia Smith: *Information required: First Name: Last Name: Comany Name: Street: City: State (Province): Country: Zi Code: Phone: Fax: 12

13 Focus Industry MANUFACTURING / 0 6 COMPRESSED AIR BEST PRACTICES Best Practices for Comressed Air Systems Desite the small share in electricity use, comressed air is an area where low-cost but relatively large savings can be found, as evidenced by some of the ENERGY STAR artners. Comressed air is by far the most costly energy carrier in almost any facility. Many oortunities to reduce energy consumtion in comressed air systems are not rohibitively exensive; in fact, ayback eriods for some otions (such as imroved system maintenance) can be extremely short. Energy savings from comressed air system efficiency imrovements can tyically range from 20% to 50% of total system electricity consumtion.the Energy Guide for cement lants rovides detailed information on a number of roven, cost-effective measures for imroving the energy efficiency of comressed air systems.a summary of the efficiency measures discussed in the Energy Guide is rovided in Table 2. Information on best ractices for comressed air system energy efficiency was comiled by LBNL from a wide variety of sources from various rograms (e.g. U.S. Deartment of Energy, U.S. Environmental Protection Agency), industry, and national and international sources. Often, lant and energy managers do not have the time, budget, or resources to obtain such detailed information on efficient technologies or imroved efficiency ractices. This lack of information can be a major barrier to industrial energy efficiency imrovement at many U.S. lants.the aim of the Energy Guide is to reduce this information barrier by roviding lant and energy managers with a concise source of state-of-the art information on energy efficiency measures alicable to their lants, while also arming them with enough basic information to understand the otential energy and cost savings associated with each measure. Comressors and Boosters for Air, Inert Gases and Natural Gas * *Pieline Quality Natural Gas Air-cooled, Single and Multistage Recirocating 300 to 7000 PSIG Discharge Pressure Sound Attenuated Enclosures Available Purification Systems Available Standard and Custom Designs Stationary and Mobile Designs APPLICATIONS Gas Recovery Injection Molding Gas Recirculation Systems Seismograhic Exloration Relief Valve Testing Air-Oil Accumulators Leak Detection Comonent Testing Dual Air/Gas System Engine Starting Boost Plant Air Natural Gas Vehicle Refueling BAUER MODEL B Stage Air Comressor HP SCFM PSIG BAUER COMPRESSORS Inc Azalea Garden Road Norfolk, Virginia Tel: (757) Fax: (757) sls@bauercom.com BAUER COMPRESSORS, INC. is registered to ISO

14 COMPRESSED AIR BEST PRACTICES / 0 6 THE ENERGY STAR FOR INDUSTRY PROGRAM Focus Industry MANUFACTURING Box 2: Comressed air system efficiency at California Portland Cement Comany California Portland Cement Comany (CPCC) oerates three clinker and cement lants in Arizona and California. The comany is an ENERGY STAR artner and was awarded the 2005 and 2006 Partner of the Year award, while two of its lants received the 2006 ENERGY STAR award for their overall energy erformance. CPCC launched a strategic cororate-wide energy management system. CPCC realized that large energy savings can be achieved by assessing the comressed air systems. CPCC cut its electricity use by 10% (or 31 GWh/year) as art of the efforts undertaken as art of the ENERGY STAR rogram. The baghouse ulse jet or lenum ulse dust collectors are a major consumer of comressed air in virtually all cement lants, whereas comressed air is also used at other miscellaneous areas in the lants. In the assessments CPCC identified the following oortunities for reducing energy use for comressed air: Shut down of the comressed air system and dust collector system when the mills are not in use Leak reduction, which at one lant alone saved over $30,000 year for a single leak Shut-off of auxillaries running idle (for which the total ower use was estimated at 0.5 MWe at a single lant) Reduction of air ressure from 85 si to 65 si Reduction of inaroriate use of comressed air (e.g. dedusting of the work floor) Use of NEMA Premium efficiency motors, whenever a motor is relaced Relacement of V-belts by cog belts Imroved maintenance. Combined the measures saved $100,000 er year for all three lants oerated by California Portland Cement Comany, and were realized at low ayback eriods. In the discussion of each energy efficiency measure, the Energy Guide tyically rovides: A brief descrition of the efficiency measure, including any limitations on alicability An estimate of tyical energy savings associated with the measure An estimate of tyical cost savings associated with the measure, including the simle ayback eriod associated with any investments An industrial case study to illustrate successful alication of the measure, when available References to ublicly-available sources of additional information Plant and energy managers are encouraged to consult the references and tools recommended in the Energy Guide to facilitate a more in-deth assessment of the alicability of any given energy efficiency measure to their secific lant. TABLE 2. SUMMARY OF COMPRESSED AIR SYSTEM ENERGY EFFICIENCY MEASURES INCLUDED IN THE ENERGY GUIDE FOR CEMENT PLANTS System ugrades and imrovements Imroved load management Imroved maintenance Pressure dro minimization System monitoring Inlet air temerature reduction Leak reduction System controls Turning off unnecessary comressed air Proerly sized ie diameters Modification of system in lieu Heat recovery of increased ressure Relacement of comressed air by other sources Additional Information For additional information on the ENERGY STAR for Industry Program, lease visit: htt:// For information Energy Guide for Cement Making, lease contact: Ernst Worrell, Lawrence Berkeley National Laboratory, eworrellt@lbl.gov. End Notes Energy Efficiency Imrovement and Cost Saving Oortunities for the Cement Industry: An ENERGY STAR Guide for Energy and Plant Managers. By Ernst Worrell and Christina Galitsky. Lawrence Berkeley National Laboratory, Berkeley, California. LBNL The reort can be found at: htt:// Based on data rovided by the United States Geological Survey s Mineral yearbooks (multile years). Estimated using energy consumtion data from the U.S. DOE Manufacturing Consumtion of Energy, 2002 and 1994 data tables, and electricity end use breakdown data for motors from U.S. DOE (1998), United States Industrial Motor Systems Market Oortunities Assessment, Office of Industrial Technologies, Washington, D.C. Efficiency Partnershi (2004). Industrial Product Guide Manufacturing and Processing Equiment: Motors. Flex Your Power, San Francisco, California. 14

15 Focus Industry MANUFACTURING COMPRESSED AIR / 0 6 BEST PRACTICES Managing Dust Collectors in Cement Production BY HANK VAN ORMER Cement roduction facilities have a significant number of dust collectors. Many have continuing roblems with short bag life and low-ressure roblems at the further oints from the central air system.they often run on timers.when they try to run on demand control, they often get extreme short cycling, which causes even more bag roblems. Most have gauges at the entry, on at least half of the dust collectors, and the comressed air feed lines are always the same size as the connector oening.this article reviews where these roblems come from and rovides some troubleshooting ideas. Proer oeration of dust collectors is critical to minimizing cost and maximizing system effectiveness.there are many sizes and most, if not all, use a ulse of comressed air controlled by a timer.the timers are generally set by the oerators to what they believe is aroriate for roer cake removal and bag life. In a dust collection system, the dust is collected on the bag or fingers and when the cake of dust is of aroriate thickness and structure a ulse or ulses of comressed air is used to hit or shock the bag and knock the cake off. When the cake is removed correctly from the dust collector, the system removes dust from its assigned environment and has a normal bag life.when the cake is not removed effectively, the dust collector does not remove dust effectively from its assigned environment and the bag life can be significantly shortened. Dust collection system designs secify the air inlet ressure to the manifold and ulse valves necessary for effective dust removal.the ulse valve sends a given volume or weight of air to the bag at a redetermined velocity to strike and clear the cake.the actual amount or weight of air is deendent uon the ulse nozzle being fed comressed air at a re-determined and steady ressure. The dust collector must receive the correct ressure (or close to it) and a steady reeatable ressure level for each ulse, articularly if timers are used to control the ulses.the oerator may exeriment to find the right timing sequence at a desired feed ressure. But if this ressure varies, then erformance may not be satisfactory. 15

16 COMPRESSED AIR BEST PRACTICES / 0 6 Focus Industry MANUFACTURING MANAGING DUST COLLECTORS IN CEMENT PRODUCTION Short bag life usually comes from the ulsers hitting the bag when the cake is not ready to flake off or the cake has gone too long between ulsing and grown too thick and heavy to clean effectively.this causes not only short bag life but very oor erformance.there are usually several basic causes for this: Incorrect timer settings for the oerating conditions. The actual requirement for the otimum timer setting may well change as various roduct runs change or even seasonally. These settings have to be set carefully to begin with and monitored regularly. Lack of sufficient storage or comressed air suly near the inlet manifold to suly the required ulse air without collasing the inlet ressure. With too low an inlet ressure, the mass weight of the air ulse is too low, which then becomes ineffective in removing the cake. Too small a feed line to the dust collector entry will have the same effect as lack of air suly. Too small or an incorrect regulator, which is unable to handle the required Rate of Flow required by the dust collectors. All of these are installations or system situations that cause restricted air flow.they occur because, rior to the installation or rior to some oerational change, the roer rate of flow was not identified for the dust collection action. Feed line sizing, regulator sizing, and air suly all require an identified rate of flow. You cannot use average flow rate. Rate of Flow Flow rate is the average flow of comressed air in cubic feet er minute either required by a rocess or delivered to the system. Rate of flow is the actual rate of flow of comressed air demand in cubic feet er minute. Even relatively small air demands in cubic feet can have a very high rate of flow, if they occur over a very short time eriod. Dust collectors have this characteristic. Sequence controllers can have a very significant imact on the required rate of flow. For examle, ictured here is a dust collector system, which has six ulsing valves that use 3.5 cu ft over 1 2 second for each ulse. 16

17 Focus Industry MANUFACTURING / 0 6 COMPRESSED AIR BEST PRACTICES Dust Collector System Pressure 100 sig 1 1 2" 4 System Pressure: 70 sig Dust Collector ulls system Pressure down 30 sig 6 Valves.5 sec 3.5 CU 100 sig Every 7 Seconds 4" 1 1 2" Tyical Sizing (Each Valve Uses 3.5 scfm/ulse 6 Valves on Collector) Rate of Flow & Sizing with One Valve Hitting Every 7 Seconds Rate of Flow & Sizing with Six Valves Hitting Every 7 Seconds Rate of Flow = Rate of Flow = (1) x (3.5) = 3.5 x 60.5 = 420 scfm (6) x (3.5) 21 x 60.5 = 2,520 scfm The line size recommendation from the air suly The line size recommendation from the air suly to the dust collector = 90 sig line ressure = 2" to 2" to the dust collector 90 sig line ressure = 4" to 6" A 2" feed line will handle the 420 cfm flow at 90 sig line ressure with a velocity of 43 fs, which is about as high as it should go A 3" feed line will handle the 420 cfm flow at 90 sig with a velocity of about 19 fs very conservative A 2" line would have a ressure loss of about 1 sid every 420 scfm flow, which may be accetable deending on feed line design and length A 3" line would have ressure loss of less than.10 sid er 420 scfm flow, which should be very accetable A 5" feed line will handle the 2,520 cfm flow at 90 sig line ressure with a velocity of about 43 fs A 6" feed line will handle the 2,520 cfm flow at 90 sig line ressure with a velocity of about 30 fs, which is conservative in this alication A 2" line at 2,520 cfm would have a minimum ressure loss of sid, deending on timing and turbulence. This would be comletely unaccetable A 4" line would have a ressure loss of about 1.1 to 1.2 sid er 90 sig and combined with moderate velocity should be accetable deending on the length and design of the feed line A 6" line would have a minimum ressure loss of sig with very low velocities and should be accetable with normal installations 17

18 COMPRESSED AIR BEST PRACTICES / 0 6 MANAGING DUST COLLECTORS IN CEMENT PRODUCTION Problem: Flow / Rate of Flow The imact of these two different rates of flow would show similar differences in regulator sizing, etc., if they are used on the feed line flow.the high flow velocities entering the manifold and controls for the ulse valves will create extra ressure loss through the balance affecting the erformance of the ulse cleaner.the same sort of effect would show u in air receiver sizing to minimize system and feed line ressure dro if that is a question. We recommend that every feed line has a quality ressure gauge installed near the dust collector entry. Observe the ressure gauge, which the ulser hits if the ressure dro is too high (over sig), start looking for the cause. Get the secification on the dust collector (cfm er ulse, feed line ressure time er ulse, cycle time between ulses, etc). Calculate the rate of flow, check line size and storage. If additional storage is required, this can be calculated by the following formula: For examle, 2,520 cfm rate of seconds flow with 4 sig allowable ressure loss. Size Air Receiver: Tmin = (V) (P2 P1 Refill Rate of Flow: (CFM) (14.5) Time allowed 6 seconds Net Rate of Flow 2,520 cfm 21 cu ft x 60 seconds 6 seconds = P1 Rest Pressure 100 sig 210 cfm rate of flow P2 Allowable Dro 96 sig (4 sig) (V) (4) (60) 240 V Effect on Header: Negligible Tsec = =.5 sec =.5 sec (2,520)(14.4) 36,540 We have used storage to convert a 240 V = 18,270 V = 76 cu ft x 7.48 = high rate of flow to a low rate of flow 570 gal or more and eliminate system ressure collase Summary:When we audit cement lants and oerations with significant dust collecting, it is very rare when we find anyone in oerations that is aware of what the dust collectors oerating secifications are and how or why the ie sizes (etc.) were selected.when you get the facts and go by the book, an amazing thing haens.they work like they are suosed to. Once you are sure the installation is correct, we always suggest running from a demand-side controller, which senses the filter condition and only lifts the bag at the right time.there are some excellent electronic control systems available, which can be very economical.this will usually imrove bag life and reduce air usage. Mr. Hank Van Ormer is a leading comressed air systems consultant who has imlemented over 1200 air imrovement rojects. He can be contacted at (740) , hankvanormer@aol.com, and Focus Industry MANUFACTURING Comressed Air Best Practices JOB MARKET ADVERTISING RATES MAGAZINE ADS For smaller classified-tye ads use the following rates er column inch: 1x er year: $94.00* er column inch 3x er year: $90.00* (i.e., this is a 10 col. inch, reversed ad) 12x er year: $84.00* *reversed ads = 1.5x normal rice Add $50.00 to ost the job oening on when you urchase an ad in the magazine Contact Patricia Smith for 4 color full age, 1/2 age and 1/3 age ad rates ONLINE ONLY ADS Each job osting is u on the site for 60 days. Postings can be urchased in bulk quantities er the rates below. The customer has twelve months to ut the ostings on the site. After twelve months, any unused ostings will be charged at the minimum quantity. Small Price Per Bulk Price Per Qty. Posting Qty. Posting 1 $ $ atricia@airbestractices.com, tel:

19 COMPANY PROFILE SULLAIR: RESPONDING TO THE VOICE OF THE CUSTOMER Comressed Air Best Practices interviewed the following executives at Sullair Cororation Elizabeth McMahon, Director of Marketing Robert Lauson, Manager of Oerations, Construction Products Rick Stasyshan, Vice President and General Manager, Industrial Products Jeff Elmore, Manager, Engineering Product Develoment & Air System Management Sullair Global Headquarters in Michigan City, Indiana COMPRESSED AIR BEST PRACTICES: Good afternoon! Wasn t Sullair a ioneer in introducing rotary screw comressors to the U.S. market? Absolutely. In mid-july of 1965, Sullair Cororation introduced rotary screw air comressors in the U.S.We had just finished celebrating our forty-year anniversary. In 1965, Sullair was one of just a few comanies working with this innovative technology. Our first roducts were 25 horseower and 50 horseower comressors for industrial users and 185 cfm and 750 cfm ortable units.the 185 cfm ortable was known as a two-tool comressor while the 750 cfm ortable was often used to ower air drills doing rock excavation. Industry was using iston and vane air comressors, which had routine maintenance and overhaul issues. Plant engineers were asking for ways to reduce the costs associated with maintaining their air comressors. Rotary screw technology offered a solution.the airend design of rotary screw comressors was able to offer lant engineers consistent erformance and reduced maintenance costs. Sullair invested significant marketing resources to educate industry and build awareness of the availability of this new technology. In the 1970 s we were extremely active with roduct demonstrations at trade shows and at end user sites. For these reasons, the market transitioned to rotary screw technology rather quickly. 19

20 COMPRESSED AIR BEST PRACTICES / 0 6 Comressed Air Industry MANUFACTURING SULLAIR Comany Profile How is the big launch of the 3700 Series Rotary Screw Comressor rogressing? The new family of Sullair 15 to 60 horseower rotary screw air comressors is being received very well.we again invested significant resources into understanding what the market is looking for. The new designs address three key market drivers: 1. Maximize Energy Efficiency Low kw consumtion was achieved through new airend designs. The fifty horseower unit is rated at 37 kw. Minimal ressure dro through the unit, was achieved with innovative ackaging designs 2. Provide Environmental, Health & Safety Features Sullair rotary screw airend Sound attenuation the 50 horseower unit has a very low 68 dba rating Bio-friendly lubricants. The standard lubricant, Sullube, is considered biodegradable. Clean design oil containment ans and SAE o-rings on flanges to ensure leak-free oeration 3. Reduced Maintenance For ease of installation, the roduct fits through normal doorways and can be transorted on a hand allet. Long-life lubricants reduce maintenance costs and time Can you describe your Voice of the Customer rocess? Sullair has a long history of listening to the customer.we started hearing about the need to reduce energy costs years ago and resonded with the then-new designs of two-stage comressors and siral-valve controllers. Sullair was offering siral-valve control for lant systems exeriencing fluctuating demand before variable frequency drives became oular. Sullair currently deloys a hase-gate design rocess called PASSPORT. This rocess requires customer feedback to move through gates in the design rocess. In this manner, the outcome is sure to meet the market drivers of our customers. Extensive work is done with distributors and with end users to gather this feedback before and during the design rocess.we conduct workshos and visit end user customers to gather this information throughout the rocess. The PASSPORT design rocess is used successfully throughout United Technologies Cororation. 20

21 Comressed Air Industry MANUFACTURING / 0 6 COMPRESSED AIR BEST PRACTICES Sullair 3700 Series Rotary Screw Comressor What benefits does being a art of United Technologies Cororation bring Sullair? United Technology Cororations is a global technology cororation with a long history of ioneering innovations.the major oerating divisions are global leaders in their fields.the divisions include Carrier, Hamilton Sundstrand, Otis, Pratt & Whitney, Sikorsky, UTC Fire & Security and UTC Power. Sullair is one of three industrial businesses oerating within Hamilton Sundstrand (Sullair, Milton Roy, and Sundyne). UTC has a quality-first hilosohy embodied in its extensive caabilities in quality control, rocess imrovement, new roduct develoment, and worldwide cometitiveness.these best ractices are brought to Sullair and hel enrich our caabilities. 21

22 COMPRESSED AIR BEST PRACTICES / 0 6 SULLAIR Comany Profile Is that what the ACE rogram is all about? Correct. UTC is committed to Achieving Cometitive Excellence (ACE).ACE is our rorietary oerating system to ensure world-class quality in our roducts and rocesses. With its relentless focus on increasing efficiency and reducing waste,ace is integral to the comany's erformance model. Facilities worldwide are using the oerating system to imrove quality and customer satisfaction while lowering cost.ace is built on three main elements: 1. A hilosohy based on the teaching of the late Yuzuru Ito, the comany's advisor on quality methodologies. This is institutionalized in Ito University, a weeklong training session run continuously at each business unit. 2. A system that hels the organization identify and solve roblems, imrove rocesses and assist with strategic thinking. 3. The cometence, commitment and involvement of the entire organization. ACE is imlemented on the micro level, with emloyees who are trained and emowered to emloy the standard rocesses across Sullair.Through a rigorous, data-driven rocess assessed by internal auditors, emloyees and their organizations rogress through the qualifying, bronze, silver and gold levels of ACE. Comressed Air Industry MANUFACTURING SUBSCRIBE NOW! COMING EDITIONS! IDEAL GIFT FOR EMPLOYEES IDEAL FOR: INDUSTRY: Plant Engineers, Plant Managers & Maintenance Managers MANUFACTURERS: Management, Sales, Marketing & Engineering COMPRESSOR DISTRIBUTORS: Every Branch Location Rates: 12-month Subscrition Number of Subscritions U.S. $55.00 $50.00 $45.00 $40.00 Canada $65.00 $60.00 $55.00 $50.00 International $95.00 $90.00 $85.00 $ WAYS TO SUBSCRIBE: * 1.) Call Patricia Smith at and use your VISA/Mastercard. 2.) us at atricia@airbestractices.com and mail your check. 3.) Mail your information and check to: Comressed Air Best Practices 161 Clubhouse Circle Fairhoe,AL Checks should be made out to Smith Onandia Communications, LLC. Questions, call Patricia Smith: *Information required: First Name: Last Name: Comany Name: Street: State (Province): Country: Phone: City: Zi Code: Fax: 22

23 Comressed Air Industry MANUFACTURING / 0 6 COMPRESSED AIR BEST PRACTICES Where does Sullair have its oerating facilities? We oerate four major facilities around the world. Our headquarters and U.S. oerating facility is here in Michigan City, Indiana. In Euroe we oerate out of Mont Brison, France.We have a facility in Australia and another in China. Wasn t Sullair one of the first western air comressor comanies to enter China? Yes.Twelve years ago when China oened its borders to western comanies, Sullair was one of the first to enter the Chinese market and begin manufacturing rotary screw air comressors.the venture has been very ositive for Sullair. It reresents the Sullair hilosohy of having a resence in major markets by roducing roducts locally, which meet the secific needs of that geograhy. Please describe the Sullair AirMetrixSM comressed air systems aroach. Sullair Cororation is organized into four oerating units: industrial, construction, OEM/units, and Customer Care by Sullair. Our rimary strategy, for industrial, is the systems aroach to comressed air which we call AirMetrix.The objective, quite simly, is to hel end reduce costs while increasing erformance.there are seven (7) comonents to the AirMetrix systems aroach. 1. Air audits: AirMetrix offers three levels of audits to better understand the air system walkthrough s, system assessments, and full audits. 2. Downstream roducts: select the aroriate demand-side roducts such as iing and air receivers for the system We again. invested significant resources into understanding what the market is looking for. 3. System controls: utilize flow controllers and Air Traffic Control techniques to ensure air ressure stability and eliminate ressure swings 4. Core roducts: select the aroriate suly-side roducts such as air comressors and air dryers for the system 5. System monitoring: manage the comressed air system with remote monitoring internet-based tools like econnect, which can send data to lant engineers and/or service roviders. 6. AirTility : outsource comressed air as a utility. Pay for only the air you use. Eliminate maintenance costs. Reduce caital requirements for the comressed air system. 7. Customer Care by Sullair : a single source for comressor fluids, arts and system accessories Thank you, Sullair, for your insights. For more information lease contact Ms. Judi Seal, Market Secialist, Sullair, Tel: , judi.seal@sullair.com, or visit

24 Cororate Headquarters in Long Island COMPANY PROFILE EXCEEDING Exectations Comressed Air Best Practices interviewed members of the uer management team of Scales Industrial Technologies, including Bill Scales (CEO), Manny Cafiero (GM of NY; Cororate CFO), Peter Scales (VP), Niff Ambrosino (GM, NJ & PA.), and Paul Shaw (GM, CT & MA.). COMPRESSED AIR BEST PRACTICES: When and how was Scales Industrial Technologies started? The comany was founded in 1966 with the oening of a small reair sho by brothers, Bill and Peter Scales. Their focus was to rovide the best and fastest service in the industry. That focus continues today with all the eole that drive it and is one of the major reasons for our continued success. Now, 40 years later with 180 emloyees, what once was Scales Air Comressor Cororation has evolved into Scales Industrial Technologies, Inc. which has become Emloyee Owned through an Emloyee Stock Ownershi Plan (ESOP) to ensure the legacy started in 1966 carries forward. 24

25 Comressed Air Industry MANUFACTURING / 0 6 COMPRESSED AIR BEST PRACTICES What is the scoe and structure of Scales Industrial Technologies today? Today the comany serves the Northeast and mid-atlantic region with over 180 emloyees dedicated to roviding customers with to-quality, energy-efficient comressed air, vacuum, medical air and rocess cooling systems. Parts and service are rovided for all systems and caabilities include major remanufacturing of, and reairs to, rocess gas comressors. We oerate six service centers, which rovide our customers with local service and suort. Each service center oerates as a virtually indeendent small business, sharing their knowledge and exertise with the others with the suort and resources of a large organization. This rovides the local markets with the agility and focus of a local service oeration and the benefits from the suort of a larger comany behind it. Please describe your organizational structure involving service emloyees. The Scales organization chart, for the ast thirty years, has laced customers at the to of the organization. Customers truly determine the services and roducts offered by Scales Industrial Technologies. Our eole make it haen, not just the service technicians and sales engineers that our customers recognize, but internal customer service, arts and sales eole, warehouse and shiing ersonnel, the alications engineers, service administration, sho machinists and mechanics, administrative assistants, and financial services eole. These are the eole that run our comany; these are the eole charged with exceeding our customer s exectations. The crystal-clear role of the suervisors, managers, general managers and the CEO is to suort one another and everyone else in the comany to service the customer. Managers are trained to focus their efforts on this most imortant factor for continued success. Management s success is determined by its ability to rovide our eole with the tools, resources, rocesses and work environment required to excel. Only when this occurs can our comany out-erform the market in service and meet our goal of exceeding our customer s exectations. How does Scales exceed customer exectations? You don t do it with fancy romises, glossy brochures or fancy buildings. We exceed customer exectations by keeing our customers best interests as our to riority and working in a fast and rofessional manner. The non-glamorous, day-to-day interactions with customers on deliveries, technical service, and alication engineering are what determine our ability to exceed customer exectations. Fast and highest-quality work, no matter what the task is, will earn the loyalty of customers. We emloy 75 service technicians across our branches and they are the ones whose erformance every day must exceed customer exectations. How do your service branches benefit from being art of a larger cororation? While all service branches are self-sufficient, we do have roduct and service secialists within the cororation who can suort the branches on highly comlex rojects. For examle, we have exerts in temerature control, rocess cooling, rocess gas comressors, centrifugal comressors, and hosital systems. The cororation also rovides legal and financial exertise for the comlex contracts requested by some of our customers. Common suort services such as human resources, ayroll, inventory management, IT, and finance are also managed at the Carle Place, NY location. This allows all Scales branches to focus on servicing our customers and exceeding their exectations. Bill Scales, CEO of Scales Industrial Technologies SIX SCALES SERVICE LOCATIONS 1. Carle Place, New York 2. Meriden, Connecticut 3.Worcester, Massachusetts 4.West Paterson, New Jersey 5. Hackensack, New Jersey 6. Sharon Hill, Pennsylvania 25

26 COMPRESSED AIR BEST PRACTICES / 0 6 Comressed Air Industry MANUFACTURING SCALES Comany Profile best interests. Sometimes they need our exertise to reair a comlex air comressor system roblem, another time it may be a rocess cooling system roblem. We built one system for a comany that was looking to control their rocess water temerature to within 1 2 C. Often, with the current energy crunch, they are looking for our exertise in energy efficiency and an energy assessment of their systems. Has that led Scales towards offering more technologies? $mart Sequencer System Strong financial management is critical to ensure the roer suort of our service emloyees. Our facilities encomass over 100,000 square feet and our warehouses carry aroximately three million dollars in finished goods and sare arts inventories. Cororate also invests in R&D. For examle, our engineers develoed an innovation, called the $mart Sequencer System. It received awards for its ability to reduce energy costs by continuously monitoring systems and automatically selecting the most energy efficient combination of air comressors to run. It was an innovation that eliminated the need for multile control systems as it could control any combination and tye of air comressors as well as all building oerating systems. What kind of customers does your comany have? We serve all tyes of facilities with a very strong focus on manufacturing lants, hositals, utilities, harmaceutical comanies, and temerature control (HVAC systems in buildings). We also have established national accounts who ask us to assist them with their comressed air systems and energy efficiency needs in their facilities across the country. What are your national accounts looking for? They count on Scales Industrial Technologies to otimize their comressed air systems. Reliable erformance, at the lowest energy cost, is what we imlement nationwide. Every situation is different. The common thread is that our customers know that we are looking out for their We often become a rocess consultant to our customers. We have had instances, for examle, where due to otential rocess imrovements, we recommended using water, instead of comressed air, for an alication. That led to our customers asking us to get directly involved with rocess cooling technologies. Another examle was where a customer was using comressed air for blowing scra, arts ejection and conveying roduct. We switched them from high ressure comressed air to low ressure air sulied by blowers. We were able to shut off more than 150 horseower in air comressors while adding a minimal amount of blower horseower. To accomlish this we had to design the nozzles and knives in-house as many of these alications cannot be done with off-the-shelf roducts. This is an examle of how our customers can and should run and direct our business. How has energy awareness and auditing changed your business? Scales Industrial Technologies has been analyzing systems to minimize energy costs for our customers for over thirty years. We did our first audit in 1973, after the first oil embargo, for a major national account. Bill Scales was teaching comressed air system efficiency seminars in the early 1970 s and he ublished many technical aers. We are very leased, for the benefit of U.S. industry, 26

27 Comressed Air Industry MANUFACTURING / 0 6 COMPRESSED AIR BEST PRACTICES to see the increased awareness of the high energy costs associated with comressed air. As a comany, we have done everything we can to assist the Deartment of Energy sonsored Comressed Air Challenge (CAC) with their educational camaigns. How do end users sort through all these energy survey offers? We focus on turning off air comressors-eriod! We advise customers to seek consultants who strive to do the same. What is best for the customer normally does not involve urchasing an air comressor or suly side equiment. Many energy surveys concentrate on the suly side to lead towards the urchase of air comressors. Scales assessments focus on the demand side; looking for reairs, imrovements, and rocess changes that can reduce consumtion and eliminate the need for additional equiment. Once we have a good understanding of the demand side requirements, we examine the suly side and then recommend measures the customer can take to reduce their energy costs which, in many cases, include turning comressors off. Scales Industrial Technologies is an Allied Partner of the Deartment of Energy and our techniques truly reflect this. Many call Bill Scales the driving force behind the DOE s Comressed Air Challenge (CAC). How is the CAC doing? We were called uon to assist with the creation of the CAC and enthusiastically resonded. Aimee McKane and others at the CAC have done a great job in calling uon the entire comressed air industry to join in the effort to educate the market on energy-saving oortunities. Scales Industrial Technologies has suorted the CAC, whenever ossible, by sonsoring workshos and writing training materials. Five of our managers are certified CAC Instructors, three are CAC Advanced Management Instructors and we continue to emhasize education for our emloyees and customers. Scales New Jersey Service Facility 27

28 COMPRESSED AIR BEST PRACTICES / 0 6 Comressed Air Industry MANUFACTURING SCALES Comany Profile Scales Philadelhia Service Facility The CAC has been very successful in heling train comressed air industry and energy rofessionals to understand air systems and recommend more energy-efficient solutions. It has also raised awareness of the savings oortunities with end users and has develoed training rograms to hel them get results. In addition to their training seminars the CAC also rovides many fact sheets, case studies and a comrehensive 350 age manual; Best Practices for Comressed Air Systems which was co-authored by Bill Scales and David McCulloch. Our hoe is that this will hel lower roduction costs, reduce downtime, and make American roducts more cometitive, which will kee manufacturing in the United States. How can distributors and comressor manufacturers work together better? Scales Connecticut Service Facility Another of the strengths of our comany is that we maintain excellent relationshis with our vendors, some sanning many years; a few were established during the origin of our comany. We recognize the critical role our suliers lay in roviding high quality roducts and how that can imact our service and customers. Our vendors recognize that distributors are a conduit for the oinions of the end user and we always encourage them to take the time to visit and listen. We consider our vendors as strategic artners and essential to our future success. What does the future hold for Scales Industrial Technologies? Going back to our organizational structure, our customers will guide our future. We will be there as a consultant and service rovider, exand our offerings, and grow in the direction which allows Scales the oortunity to exceed exectations. Thank you for your insights. For more information lease contact: Bill Scales, CEO, Scales Industrial Technologies, tel: or visit

29 IT S TIME FOR 0ZERO AIR-LOSS BEKO TECHNOLOGIES Comressed Air Best Practices interviewed Manfred Lehner (Managing Director), Tilo Fruth (General Sales Manager) and John Hays (Oerations Manager) of BEKO Technologies COMPANY PROFILE COMPRESSED AIR BEST PRACTICES: WHAT IS THE HOTTEST TOPIC OF CONVERSATION THAT YOU HEAR FROM THE MARKET? Without a doubt, it is energy savings. Air comressors or rather the energy they consume reresent a significant ortion of the industrial energy bill in the United States and in every other major economy in the world. Currently, in the U.S. alone, comressed air systems account for $1.5 billion er year in energy costs. We have also seen an increase of 10%, on the average rice of electricity, in the industrial sector in U.S.. Rates have risen from 5.35 cents er kilowatt-hour in 2005 to 5.94 cents in Conservative estimates conclude that 15% to 25% of the energy used could be saved. The otential ositive imact on comany rofits as well as on the environment is enormous. One million BEKOMAT zero air-loss drains installed worldwide At BEKO we have always taken energy conservation very seriously. This is desite the fact that, until recently, energy consumtion and the related costs were often overlooked. The absolute heart of our comany is the BEKOMAT zero air-loss, electronic level- controlled condensate drain. Condensate drains designs have historically used comressed air to discharge liquids from the air lines. The BEKOMAT is designed to discharge the liquid without using any comressed air. The innovative design uses a atented liquid sensor with two sensing oints, inside the drain, which tell the drain valve when to oen (to discharge liquid) and close (before any air is lost). 29

30 COMPRESSED AIR BEST PRACTICES / 0 6 Comressed Air Industry MANUFACTURING BEKO TECHNOLOGIES Comany Profile Timed solenoid-valve drains are a traditional drain design, for examle, which use comressed air to discharge liquids. A 3 32" timed solenoid-valve wastes $630 of comressed air er year and a 7 16" timed solenoid-valve can waste $5,040 er year. Other drain solutions have included neumatic ball-valves (costing $1,182 er year) and 1 2" manual ball-valves cracked oen 1 8" (costing $3,590 er year) in wasted air. The worst-case scenario is a V-notch valve with a v oening of 3 8" (costing $31,980 er year) in lost comressed air. (These costs assume 100 sig, an orifice coefficient of 0.65, and a cost of $0.41 er 1,000 cubic feet of comressed air.) End users have been recognizing this oortunity to save energy. In 2005, we assed the historic milestone of the 1,000,000th BEKOMAT sold.the return on investment in the vast majority of installations is realized within 90 days and is guaranteed to not exceed six months excet in the rarest of cases. We see BEKO continues its growth. Please give us a short history and how large is BEKO now? BEKO Technologies GmbH was founded in 1982 by Mr. Berthold Koch, hence the name BEKO from the first two letters of his first and last name resectively. Mr. Koch ioneered new technologies for the comressed air business, beginning with the BEKOMAT drain. Mr. Koch continues to actively manage and lead the organization today. BEKO Technologies now oerates three manufacturing facilities and thirteen branch offices around the world. BEKO has grown to emloy two hundred and thirty highly skilled emloyees around the world and is headquartered in Neuss, Germany. The U.S. subsidiary, BEKO Technologies Cororation, has been oerating in the United States since BEKO Technologies serves the United States, Canada, and Mexico markets. The comany is currently exanding its sales resonsibilities into Central and South America Functional Descrition of the BEKOMAT Condensate Drain Emty state: Condensate trickles through the inlet oening (1) and collects in the reservoir (2). The diahragm valve is closed, since the ilot suly line and the solenoid valve (4) ensure ressure comensation above the valve diahragm (5). The larger surface area above the diahragm results in a high closing force so that the valve seat is tight and leak roof. Filled state: When the reservoir (2) has filled with condensate and the caacitive level sensor (6) signals at the maximum oint, the solenoid valve is energized and the area above the valve diahragm is vented. The valve diahragm lifts off the valve seat (7) and the ressure in the housing forces the condensate into the discharge ie (8). The BEKOMAT electronic system now calculates the discharge rate down to the minimum oint and uses this figure to determine the exact valve oening eriod required. The valve will again be fully closed and leak roof before any comressed air can escae. Should the condensate discharge fail to function roerly (i.e. blocked discharge ie or faulty diahragm), the device will go into alarm mode after 60 seconds. In this case, the red LED flashes and, if desired, the alarm signal can be relayed via a otential-free contact to an inut of your choice. While in the alarm mode, the solenoid valve will oen every 4 minutes for a eriod of 7.5 seconds in an attemt to correct itself automatically. This ensures that a filled BEKOMAT unit in an un-ressurized state will, under ressure, automatically revert to normal oerating conditions and thus clear the alarm.

31 Comressed Air Industry MANUFACTURING / 0 6 COMPRESSED AIR BEST PRACTICES What is fueling this growth? Naturally there are several factors that have contributed to this growth; one in articular is the exansion of our roduct offering.we have come a long way from just roducing and selling condensate drains. BEKO now offers comlete solutions for every asect of a comressed air distribution network in a lant. From the comressor outlet to the oint-of-use, we offer solutions for the drying and filtration of comressed air in addition to our traditional condensate management technology. Many of these technologies are atented and unique to BEKO, thereby roviding entrance for BEKO into sales channels that we reviously did not have access to. For examle, we recently introduced the BEKOKAT to the market, which is a catalytic conversion system.the roduct rovides oil-free comressed air with a maximum residual oil content of arts er million. The installation of a BEKOKAT unit, immediately downstream of a 20-year old oil-flooded screw comressor, will rovide a customer with a virtually oil-free system. Another new technology fueling our growth is the BEKOBLIZZ.This system is a dee cooling system designed secifically for blow molding alications. Installed right before the blow molding machine, the BEKOBLIZZ rovides the user with an outlet air temerature of -31 F or -49 F, deending on the alication requirements which can be blown directly into the mold.the introduction of dry, dee-cooled comressed air into the mold has roven to reduce cycle times dramatically by shortening art-cooling times, imroving overall art quality and consistency, and reducing re-grind.the net result is a imrovement to the roduction outut and rocess. The otential. ositive imact on comany rofits as well as on the environment is enormous. Aside from our roducts; the single most imortant asset of any comany and an absolute requirement for growth, are the eole working for the comany. BEKO has dedicated emloyees around the world, all of whom have a conviction about the comany and its roducts that is unaralleled. BEKO emloyees also receive continuous training on our entire roduct range, which allows us to offer services and technical exertise that are of the same quality and reliability as our roducts. We recently started a roject to establish a worldwide e-learning latform, which is nearing comletion, in order to rovide this same suerior level of roduct training, education, and awareness to all of our customers. If it were not for our dedicated emloyees and an ongoing desire to learn, growth would be imossible. Where are your manufacturing facilities and what do they roduce? The main manufacturing facility is in Neuss, Germany where the vast majority of our comressed air treatment and condensate management roducts are roduced. We also oerate a manufacturing facility in Bend, Oregon where we roduce our membrane fibers and bundles, the core of our DRYPOINT M Series of membrane air dryers. Beginning in 2007, the Bend facility will exand it s caability to include final ackaging of the membranes into housings.at this oint, all DRYPOINT M Series membrane air dryers for the North and South American market will be 100% manufactured in Bend. In addition to these two facilities, we will oen a third manufacturing site, early in 2007, in India.The roducts roduced there will be exclusively for the Indian market and not sold elsewhere. BEKO membrane bundles in roduction in Bend, OR 31

32 COMPRESSED AIR BEST PRACTICES / 0 6 Comressed Air Industry MANUFACTURING BEKO TECHNOLOGIES Comany Profile Where are the thirteen distribution centers? We have branch offices in France, Great Britain, Italy, Netherlands, Sain, and of course Germany, which make u the Euroean subsidiaries. In Asia we have two locations in China, lus subsidiaries in India, Jaan,Taiwan and Thailand. And finally the location here in Mooresville, NC that is resonsible for the Americas. Please describe your North American oerations. Mr. Tilo Fruth, General Sales Manager We have a office and warehouse in North Carolina, the rimary function of which is to serve as a distribution center for our roducts.all of the financial, marketing, sales and technical suort activities are handled out of the Mooresville, NC location.as art of our sales strategy, we have divided the United States into distinct regional sales territories, each with a resonsible Regional Manager who lives and works within that region.this area of the business is managed by our General Sales Manager, Mr.Tilo Fruth. Much of our success has been built on the foundation of our long-term artnershis with various Key Accounts and our excellent network of distributors, which for BEKO means keeing the sales force nearby and readily available to those who matter the most to us, our customers. In Canada, we have a financial interest in CAG Purification, Inc., located in Oakville, Ontario.We have together created an exclusive, long-term sales artnershi for BEKO roducts in the Canadian market. Finally, there is BEKO Membrane Technology, which is the manufacturing facility in Bend, OR that was mentioned earlier. BEKO Membrane Technology, or BMT for short, is actually a 100% daughter comany of the U.S. entity BEKO Technologies Cor. BMT is strictly a manufacturing facility and is not involved with sales or direct customer suort.the decision-making and management of the comany, however, is handled comletely by local management in Bend with almost zero influence from Mooresville. Concerning your comressed air dryers, it seems that these are now an imortant art of the BEKO roduct ortfolio. What are the advantages and alications? When drying comressed air, one should always kee in mind to dry the air to suit the alication, in accordance with quality requirements. Everything else is a waste of time and energy. Refrigeration dryers are suitable for medium and high volume flows requiring a ressure dewoint between 32 and 51 F. Our DRYPOINT RA dryers deliver this with the added advantage of a vertical heat exchanger arrangement where the condensate flow is from to to bottom. 32

33 Comressed Air Industry MANUFACTURING / 0 6 COMPRESSED AIR BEST PRACTICES Membrane dryers are, the majority of the time, only suitable for the lower volume flows, due to the available sizes. But this is not a disadvantage. Our DRYPOINT M Series membrane dryers have roven to be the erfect solution for oint-of-use drying.this includes the new DRYPOINT M PLUS Series that has integrated nano re-filtration built directly into the housing.the fact that we use our CLEAR- POINT filters and BEKOMAT condensate drains to equi our dryers goes without saying. How has condensate management evolved in Euroe and in the U.S.? 25 years ago condensate management was non-existent in Euroe, the United States and Asia.The industry didn t even know the term condensate management. BEKO is roud that condensate management actually started with the invention of the original, electronic zero air loss drain, BEKOMAT, from Berthold Koch and subsequently the oil water searator ÖWAMAT. Times have changed and as the industry evolved and rogressed, eole became aware that condensate management, which is the reliable discharge and treatment of condensate, is robably the most imortant link of the comressed air chain.why because for too many decades it was the weakest link! In Euroe condensate management is more advanced because BEKO started its business in Germany and Euroe is basically the home market.while the regulations are no more stringent than in the States, they are more strictly enforced.this of course is a consequence of the much higher density of the oulation and the industry, lack of available land, and the resulting high riority given to green industry. 3 Questions for Mr. Berthold Koch, Chairman of the BEKO Grou Q1: Mr. Koch, next year BEKO will celebrate its 25th anniversary. What is BEKO s osition in the market today? BK: BEKO stands for customer oriented solutions and high quality roducts with excetional Mr. Berthold Koch, Chairman benefits. With BEKO, comressed of the BEKO Grou air users don t have to worry about their air treatment or condensate management any more. But, and that is also very imortant, they can be sure that BEKO will be a artner at their side for years to come. We have grown strong over the years, and we are indeendent. There is no joint stock comany ulling strings in the background. Each BEKO branch office around the world is a rofitable working organization. In short: We are here to stay. Q2: What is your vision for the comany? BK: That is easy to tell, because actually we have a formulated vision for our worldwide organization. We want to kee our customers and our emloyees satisfied. We want to imrove our roducts, our service, and our way of doing business continuously. And we want to be the benchmark for our customers and our cometition in all target areas. That this vision is linked with revenue and rofit targets is self understood. Q3: Where do you see trends for growth in the U.S. market for BEKO? BK: Comressed air as a roduction medium needs quality and oerational reliability, while maintaining economic efficiency. That is what makes our roducts and services necessary for every comressed air alication. For an established industrial ower-nation like the USA, our roducts and services are becoming even more imortant. With our new energy-saving air treatment and condensate management roducts, we will contribute to reduce the overall energy costs in the US. BEKOMAT Zero Air-Loss Condensate Drains 33

34 COMPRESSED AIR BEST PRACTICES / 0 6 Comressed Air Industry MANUFACTURING If you look at highly oulated metroolitan areas (Atlanta, Boston, Los Angeles, etc.) in the U.S. you see the same strict enforcement of these regulations by the EPA. When drying. comressed air, one should always kee in mind to dry the air to suit the alication, in accordance with quality requirements. And we know this first-hand; several comanies in those areas contacted us for hel because they received fines or were close to being fined because of environmental ollution.the sad thing is, esecially in the more rural, less oulated areas where there is a lot of manufacturing and growth going on, the majority of our customers and even otential customers have no idea that we have an easy, reliable, and energy saving solution; which is articularly imortant in these areas, now more than ever, with the imending increases in energy costs. With all your activities in comressed air treatment, is condensate technology still a riority for BEKO? Condensate management will never lose its imortant status within our roduct ortfolio. Condensate technology is where we come from and is where our roots are. BEKO remains the number one condensate exert in the world.that is exactly why we work on new roducts in this area like our new BEKOMAT 31 and 32 that we just introduced to the market in October. In the first quarter of 2007 we will debut a brand new ÖWAMAT series of oil/water searators. We are not just reackaging our standard gravity-tye searators-these new designs are truly revolutionary! Offering true advancements in condensate management technology kees BEKO on the cutting-edge and years ahead of the cometition in this segment of our business. Concerning condensate, do you see different laws governing the disosal of oil in condensate systems? Quite simly, no we do not.there is a bottom line here; it is unlawful to dum, discharge, or disose of any untreated condensate into the environment regardless of how it was created or disosed of.the EPA is quite clear about this; so much so that Plant Managers, Engineers, Oerators, etc. can be held liable, as individuals, with enalties ranging from fines in the tens of thousands of dollars to jail time deending on the severity of the infraction. Thank you BEKO Technologies for your insights. For more information or to subscribe to our monthly newsletter lease contact: BEKO Technologies, tel: , beko@bekousa.com, or visit our web site at

35 Technology MANUFACTURING / 0 6 COMPRESSED AIR BEST PRACTICES TWO- STAGE Rotary Screw Air Comressors BY HARISH SHAH AND MARK PFEIFER Two-stage (also known as tandem) rotary screw air comressors offer comressed air users, looking for higher efficiency and reliability, an alternative to single-stage air comressors. For comressed air systems with fluctuating demand, two-stage designs can offer otimal energy efficiencies as both a full-load machine or as a trim machine. Two-stage Tandem Design In a two-stage air comressor, comression work is slit equally between two sets of airends. Processing the air through these two airends (or stages) is the fundamental design difference from the traditional single-stage (or one airend) design. For a 100 sig alication two-stage designs take the inlet air at 14.5 sia and comress it to sia in the inter-stage. The second stage will then comress the air to sia (100 sig). Inter-cooling between the stages is achieved by injecting cool oil into the discharge air after the first stage. This air-oil mixture reduces the effective air temerature before comression begins in the second stage. The result of this design is an extremely efficient comression ratio of 2.8 for both stages. In a traditional single-stage design, ambient air is drawn into the comression chamber at 14.5 sia (allowing for a slight ressure dro due to the inlet filter). The air is then comressed to 100 sig (114.5 sia) in one stage with a single airend set. The comression ratio of a single-stage design is

36 COMPRESSED AIR BEST PRACTICES / 0 6 Technology MANUFACTURING TWO-STAGE ROTARY SCREW AIR COMPRESSORS Two-stage designs exerience lower internal losses (air leakage), than single stage designs. This is due to the reduced ressure differences between discharge ressure and inlet ressure in both stages. The two-stage design sees a gradual ressure rogression from 14.5 sia (ambient intake) to sia (interstage) to sia (outlet discharge). Lower internal losses increase the efficiency of the two-stage design and allow for higher ressure caabilities. The reduction in ressure differential between inlet ressure and discharge ressure, in two-stage vs single-stage designs, laces reduced loads on the discharge bearings in the airends. This reduced load will result in longer bearing life and more infrequent airend relacement/maintenance. Full-load Oeration Two-stage designs will rovide, at full load, 11 13% savings over single-stage air comressor designs. Due to the more efficient comression ratios and reduced internal losses, secific ower consumtion in terms of kw er 100 cfm is reduced. A tyical single stage comressor will consume kw er 100 cfm delivered. A two-stage comressor will consume kw er 100 cfm delivered (100 sig discharge and 140 F injection temerature). Partial-load Oeration Two-stage designs can be equied with either Variable Seed Drives (VSD) or with Variable Dislacement Controls (Siral Valve) to further increase efficiencies when the same machine is faced with artial-load oerating requirements due to fluctuating demand for comressed air. The advantage is that the same machine rovides otimal energy efficiency in both full load and artial load conditions. Choosing between Variable Seed and Variable Dislacement controls is a lant-secific decision to be made. Siral Valve Variable Dislacement Control The siral valve activates automatically, when the unit is oerating under artial load, and allows the comression of only the required quantity of air. In this manner, the siral valve increases the efficiency of the comression rocess at % loads. Siral valve control allows some intake air to return to the comressor inlet.this action effectively reduces the rotor length and energy consumtion. 36

37 Technology MANUFACTURING / 0 6 COMPRESSED AIR BEST PRACTICES The siral valve rogressively oens byass orts connecting the comression chamber to the comressor intake in resonse to rising discharge ressure. As the discharge ressure rises (because more air is being roduced than used), the siral valve turns and oens internal byass orts, which revents some intake air from entering the comression chamber and consuming ower. The rogressive oening of byass orts has the effect of reducing the length of the rotors after the lobes seal (and thus the dislacement of the comressor) without choking the intake. This revents a vacuum which causes the comression ratio to increase. Variable Dislacement Energy Savings A variable dislacement control matches comressor dislacement to the outut need. It rovides significant ower savings at art-load conditions when comared to comressors using load/no load or modulation controls. Comressor Control Method Performance Comarison RED LINE: Actual Load/No Load Control BLUE LINE: Modulation Control GREEN LINE: Siral Valve Control PURPLE LINE: Theoretical Load/No Load Control Before a comressor can realize ower savings with a load/no load control, the machine must first run into the uer range of modulation which can be as high as a 10 sig band before the machine will unload. This 10 sig unload oint will cost a customer 5% of the motor horseower on average. When the machine unloads it is done through a blow-down valve which takes several seconds to blow the air that is ressurized in the sum to atmoshere. As the demand calls for more comressed air, the machine must now reressurize the sum to rovide more system air. Power Comarison of 300 horseower Models RED LINE: Single-stage, 300 h comressor with modulation control BLUE LINE:Two-stage, 300 h comressor with load/no load control (based uon 1 gallon er cfm air storage) GREEN LINE:Two-stage, 300 h comressor with siral valve variable dislacement control 37

38 COMPRESSED AIR BEST PRACTICES / 0 6 TWO-STAGE ROTARY SCREW AIR COMPRESSORS Modulation controls are one of the most common tyes of controls used on rotary screw comressors. Modulation control utilizes either an inlet butterfly valve or neumatic inlet valve. As the lant ressure and caacity is met, the inlet to the comressor starts to close off. This limits the airflow through the rotors housing reducing the amount of air being comressed. The inlet valve modulates its osition based on the system requirement. Two-stage tandem air comressors offer efficiency advantages at both full load and artial load oerating conditions. Siral valve or VSD technology can further otimize the design for artial load conditions. Mr. Harish Shah is an Advisory Engineer, Industrial Sales & Marketing and Mr. Mark Pfeifer is the National Accounts Manager, Industrial Division, at Sullair Cororation. For more information lease contact Ms. Judi Seal, Market Secialist, Sullair,Tel: , judi.seal@sullair.com, or visit Managing a Harsh Environment Technology MANUFACTURING The ambient environment for air comressors, at cement lants, can be harsh. Air comressors oerate like a giant vacuum um inhaling ambient air along with everything entrained in the air. Cement dust is very abrasive and can severely affect the efficiency and longevity of a rotating iece of equiment like an air comressor. Once ingested into the comression chamber of the air comressor, this abrasive dust will wear on comonents and ultimately cause remature failure. Comressor manufacturers offer filtration ackages to combat harsh ambient conditions. Heavy-duty and high-dust intake filter arrangements are available. These filters will revent cement dust from entering the comression chamber. The key is to have an effective maintenance rogram on the filters. Filters that collect dirt and begin to clog cause a change in the atmosheric ressure. This vacuum effect can reduce the efficiency of the air comressor. The ideal solution is, of course, to find a way to rovide the air comressor with a steady stream of clean, cool air in a ositive ressure environment. If this is imossible, regular maintenance of the filter elements is much less exensive than a 5% reduction in comressor efficiency. Reliable comressed air. is critical to the oeration of dust collectors in our cement lant. We have been very leased with the consistent quality and quantity of air from our five two-stage air comressors. With good maintenance and reventative ractices we continue to save over $50,000 er year in energy, while deferring the caital exense of airend relacements. Plant Manager Cement Plant in South Dakota 38

39 Technology MANUFACTURING COMPRESSED AIR / 0 6 BEST PRACTICES AUTO SURVEILLANCE MODE Adds Efficiency to Vacuum Alications BY BOB BUERKEL Many manufacturing rocesses emloy vacuum systems for ick and lace oerations. By adding a ressure sensor with Auto Surveillance features, users can reduce machine cycle time and add reventative maintainence features that hel minimize downtime and droed arts, while increasing throughut of the machine. General Vacuum Alications A vacuum system includes all comonents that are connected to the vacuum generator or vacuum um.vacuum generators are designed to reach a Maximum Degree of Vacuum (MDV).This value is obtained given a secific comressed air inlet ressure and flow. When the vacuum generator is turned on and the cus are off the art, the degree of vacuum created in the system is less than the required alication ressure. This is called Part Off ressure (See Figure 1).The ideal ressure for vacuum cus to lift and hold arts with a vacuum seal is referred to as Part On ressure. This value can be a rogrammed set oint on a ressure sensor (H-1).When the vacuum cus create a seal on the art, the system vacuum ressure increases from Part Off ressure to Part On ressure.this ressure is an alication-secific design level between "Part Off" and MDV. Samling. cycles can be increased by rogramming the ressure sensor to monitor u to 100 cycles. 39

40 COMPRESSED AIR BEST PRACTICES / 0 6 Technology MANUFACTURING AUTO SURVEILLANCE MODE ADDS EFFICIENCY TO VACUUM APPLICATIONS Pressure sensors tyically have a resonse time of less than 2-milliseconds and incororate oen collector oututs to deliver inuts to the machine PLC for Part On signals. Comared with slower mechanical switches, it is this resonse time that reduces the automation cycle time. To further imrove resonse times, ressure sensors are available with two indeendent oututs. Outut 1 can be rogrammed to anticiate Part On ressure. Outut 2 (H-2) can be rogrammed to confirm either actual rogrammed system design level or MDV.When the system ressure has obtained the value of H-1, the degree of vacuum continues to increase. Designers rogram Outut 1 to signal the PLC to start the next automation sequence at H-1. By the time the neumatic valves and cylinders react in the automation rocess, the ressure of the vacuum system will have increased to a level at or above actual system design level. By anticiating this ressure, the automation rocess is started sooner, reducing overall cycle time. Factors that Reduce MDV There are a number of factors that can reduce the Maximum Degree of Vacuum in a system.vacuum generator manufacturers usually designate an otimum suly ressure and flow rate to create MDV. However, most systems never achieve the Maximum Degree of Vacuum as rated by the manufacture because of system inlet ressure and flow restrictions or because of some tye of leakage by the cu seal or through the roduct being held. For instance, decreasing or increasing the inlet ressure or airflow reduces the Maximum Degree of Vacuum created by the system (See Figure 2).Tubing and fittings that connect the vacuum generator and vacuum system can become loose, creating leak oints. MDV can be decreased by vacuum cu seal leakage and/or through the roduct itself (See Figure 2a) Cus can wear, tear or harden due to the effects of the working environment. Leakage through the cu seal into the vacuum system decreases the maximum degree of vacuum. In orousroduct alications, the roduct held by the cu causes leakage through the roduct as well. In general, vacuum alications are not designed to oerate at the Maximum Degree of Vacuum because of resonse-time and safety issues. 40

41 Technology MANUFACTURING / 0 6 COMPRESSED AIR BEST PRACTICES The Auto Surveillance Mode and How it Works A ressure sensor with Auto Surveillance Mode has 2 oen collector oututs (See Figure 3). Outut 1 is used for Part On signal, enabling the machine "logic" to advance to the next ste in the rocess. Outut 2 is rogrammed to the Auto Surveillance Outut and monitors the Peak Degree of Vacuum (P-1) in every vacuum cycle. Users can change the values of H-1 and P-1 with ush button rogramming keys to suit the alication s arameters. P-1 can be automatically set to about 80% of Maximum Degree of Vacuum, which is a value between MDV and the Part On level. Because MDV can change during the life of the vacuum system, setting Outut 2 at MDV is not always otimal. Some ressure sensors have additional rogramming features that change Outut 2 of the sensor to an Auto Surveillance Mode. This mode is actually a failure rotection indicator.that is,auto Surveillance Mode monitors the Maximum Degree of Vacuum obtained in each automation cycle and alerts the system if the rogrammed eak degree of vacuum ressure has been not been obtained, indicating that the system should be checked. Illustration of a Successful Cycle The vacuum system is turned on and system ressure achieves Part Off ressure. When the vacuum cu array seals on the roduct, Part On ressure (H-1) is reached and Outut 1 changes state, enabling machine "logic" to advance to the next ste in the rocess. Vacuum ressure continues to increase beyond the Peak Degree of Vacuum setting (P-1) and aroaches the system s Maximum Degree of Vacuum.Vacuum is then turned off and the roduct is detached from the cu array.when vacuum is turned off, degree of vacuum returns to a level below H-1. In this successful cycle, the critical ressure to be obtained is the Peak Degree of Vacuum (P-1).The Auto Surveillance Mode monitors the rocess to ensure that the system s degree of vacuum surasses Part On ressure and exceeds the rogrammed Peak Degree of Vacuum. In an unsuccessful cycle, the rocess is the same as above excet that the vacuum ressure does not increase ast Peak Pressure (P-1).The automation rocess continues, however, because Part On ressure was obtained.when vacuum is turned off, the degree of vacuum decreases to a level below H-1. Because P-1 was not obtained during the vacuum cycle, the second outut of the sensor changes to a assing state for 3 seconds. Comressed Air Best Practices JOB MARKET ADVERTISING RATES MAGAZINE ADS For smaller classified-tye ads use the following rates er column inch: 1x er year: $94.00* er column inch 3x er year: $90.00* (i.e., this is a 10 col. inch, reversed ad) 12x er year: $84.00* *reversed ads = 1.5x normal rice Add $50.00 to ost the job oening on when you urchase an ad in the magazine Contact Patricia Smith for 4 color full age, 1/2 age and 1/3 age ad rates ONLINE ONLY ADS Each job osting is u on the site for 60 days. Postings can be urchased in bulk quantities er the rates below. The customer has twelve months to ut the ostings on the site. After twelve months, any unused ostings will be charged at the minimum quantity. Small Price Per Bulk Price Per Qty. Posting Qty. Posting 1 $ $ atricia@airbestractices.com, tel:

42 COMPRESSED AIR BEST PRACTICES / 0 6 Technology MANUFACTURING AUTO SURVEILLANCE MODE ADDS EFFICIENCY TO VACUUM APPLICATIONS In general,. vacuum alications are not designed to oerate at the Maximum Degree of Vacuum because of resonse-time and safety issues. At this oint, the MDV in the system has decreased below the P-1 setting.this signal is a warning to the user that the degree of vacuum in system has been comromised.auto Surveillance Mode alerts the system oerator that maximum degree of vacuum of the system is still above H-1, art resent, but it has decreased to an unsafe level and that the system should be checked during the next scheduled downtime for maintenance.as exlained earlier, reasons for a not obtaining P-1 can include a change in inlet ressure or inlet flow, loose fittings, deteriorated cu seals, or a change in roduct orosity. If left unchecked, a further decrease in degree in vacuum may result in droed arts, causing an increase in scrae rate and machine down time that reduces throughut of the automation rocess. Monitoring every cycle may be too often for some alications. Samling cycles can be increased by rogramming the ressure sensor to monitor u to 100 cycles. If P-1 is not obtained in 100 cycles, Outut 2 will change to a assing state for 3 Seconds. If P-1 is obtained anytime during the 100 cycles, the ressure sensor resets the cycle count and starts monitoring the next 100 cycles. Extended monitoring allows the user to make sure that the failure to obtain P-1 isn t a fluke and that it is, in fact, a ersistent roblem. Benefits of Auto Surveillance Mode Sensors with the Auto Surveillance Mode reduce the annual cost associated with relacing vacuum cus. Some users change every cu during a routine maintenance cycles based on standard time intervals. Instead of relacing all cus, only the cus that are causing leakage have to be relaced.auto surveillance rovides an alert when the MDV has decayed and, deending on usage, this may extend the standard time interval and increase the hours of use of each cu. Just as Outut 1 (H-1) can be used to anticiate art resent and send a signal to the PLC decreasing machine cycle time,auto Surveillance Outut (P-1) can be used to anticiate machine downtime.though the vacuum cycle is still reaching H-1, the system s eak degree of vacuum may be decreasing over time. Without the system monitoring rovided by Auto Surveillance, it s robable that the eak degree of vacuum will decrease to a oint of droing a art or failing to reach H-1. Both events can cause machine downtime and decrease roduct throughut. However, because the system is alerted, maintenance can be erformed to return the vacuum system to otimum erformance before system failure. Sensors with Auto Surveillance Mode revent machine downtime, reduce oerating costs, minimize droed arts and reduce scra while increasing roduction throughut and rofits. For more information, lease contact Bob Buerkel, Product Manager, Vacuum and Pressure Sensors, Parker Hannifin Cororation, tel: , bbuerkel@arker.com 42

43 Comressed Air Industry MANUFACTURING / 0 6 COMPRESSED AIR BEST PRACTICES INDUSTRIAL MARKETING On-line Marketing for Industrial Comanies BY ROD SMITH Increase Brand Awareness In last month s column we talked about roviding value to the visitor of your comanies web site. Most eole don t visit an industrial web site for entertainment. If they come to the site, make it worthwhile for them by roviding easy knowledge-transfer to them.that is what they are looking for. Some surveys indicate that a high ercentage of caital equiment urchasers turn to the web to begin researching otential vendors. This month we will discuss how to drive eole to your comanies web site and thereby increase brand awareness. Marketing your domain name and using Search Engine Otimization (SEO) techniques are the recommended methods. Marketing the Industrial Domain Name How can we make eole aware of our domain name? We don t do television ads! While I know a good industrial magazine I d recommend advertising in, focus first on the basics.what your comany does every day rovides the best marketing oortunity. 1. Stylize the domain name into your comany logo or find a way for it to aear in all comany stationary. 2. Place the domain name rominently on all machines you manufacture and/or sell. This is what end users will see the most over the next 7 years. Don t be modest about it either! Search Engine Otimization Books are written on this toic but I ll try to condense it into a aragrah.the whole idea is to show u on the first age of a Google search engine screen when an end user tyes in a key word of interest to you like air comressor. 1. Hire a good firm with references and strong links into Google. Once you do well with Google, start worrying about other search engines. 2. They will modify the source code of your web site so it is seen by the search engines and laced on the first age no need to do search engine ads. 3. They will start tracking your ranking on major search engines (by age and by key word). Just choose two or three key words and do well with them. 4. Every month, you should track unique visits er day. This tells you how many eole came to your web site every day. Watch out for other metrics like visits which count for every age a visitor clicks on. Increase your industrial brand awareness with a focused strategy on driving customers to your web site. This is the second of three articles on on-line marketing. Rod Smith is the former Vice President of Sales & Marketing for Hankison, PPC, & Deltech (divisions of SPX Cororation) and for Quincy Comressor (a division of EnPro Industries). For more information: rod@airbestractices.com or tel: Develo a uniform sign-off, which includes the domain name, for all emloyees of your comany. Think about how many s reach customers every day. Invite that customer, who is on-line reading your , to click on a link to discover something interesting that will hel their business. 43

44 COMPRESSED AIR BEST PRACTICES / 0 6 Comressed Air Industry MANUFACTURING INDUSTRYNEWS Press Releases New Air Services from Festo ENERGY SAVING SERVICE Learn how cutting comressed air consumtion can save you money with the Festo Energy Saving Service! Using comressed air more efficiently hels save money. Generally, there is a otential savings of u to 35% of the energy costs of neumatic systems through better maintenance. Festo now offers individual services to customers wishing to achieve more efficient use of comressed air. For more details, lease visit: Festo is a leading global manufacturer of neumatic and electromechanical systems, comonents and controls for industrial automation, with 56 national headquarters serving more than 180 countries. For more than 80 years, Festo has continuously elevated the state of manufacturing with innovations and otimized motion control solutions that deliver higher erformance, more rofitable automated manufacturing and rocessing equiment. Our dedication to the advancement of automation extends beyond technology to the education of current and future automation and robotics designers with simulation tools, teaching rograms, and on-site services. The Energy Saving Service covers everything from consumtion and leakage measurements through to machine insection and final analysis. Festo Contact Information for ublication: Tel: FESTO; Fax: FESTO customerservice@us.festo.com Website: Festo Energy Saving Service includes: Consumtion and Leakage measurements Analysis of consumtion and leakage measurements Machine Insection inoint leaks; analysis of weak oints Machine Reair assistance in elimination of leaks of defective comonents Final Analysis cost/benefit analysis; documentation With the Energy Savings Service, you can exect: Increased Productivity significant reduction in energy costs Increased Process Reliability rofessional maintenance of neumatic systems Environmental Protection reduced energy consumtion cuts down on the greenhouse effect All resulting in reduced energy usage, reduced downtime and greater roductivity! 44

45 Comressed Air Industry MANUFACTURING / 0 6 COMPRESSED AIR BEST PRACTICES HITACHI BRINGS OIL FREE AIR TECHNOLOGY PRODUCTS TO NORTH AMERICA TARRYTOWN, NY, October 1, 2006 Hitachi America, Ltd., Industrial Systems Division, today announced entry into North America with its Air Technology Grou Products. Providing value via technology is the cornerstone of the Air Technology Grou, leveraging the alications exerience and efficiency of Hitachi inverters, motors and comressors. To fulfill requirements for a wide variety of customers,air Purity is achieved via incororation of Oil-Free Rotary Screw, Oil-Less Scroll & Oil-Free Vortex Blower comressor technologies. Hitachi s Air Technology Grou Products are incororated into many market alications such as medical, food & beverage, harmaceutical, electronics, etc.with nearly 100 years of exerience in air comression, Hitachi is able to rovide the customer with roven, reliable and efficient otions. Hitachi s Air Technology Grou is to be based in Charlotte, NC.The facility will be the center for all Air Technology Grou business oerations, warehousing, and training for Distribution Partners and OEMs. For more information, lease visit or contact Nitin G. Shanbhag at airtechinfo@hal.hitachi.com. Hitachi America, Ltd., Industrial Systems Division, sulies a broad range of industrial roducts and services. The division sulies sohisticated industrial equiment, comonents and services for alication in harmaceutical lants, food & beverage rocessing, steel making, mass transit systems, chemical lants, and other manufacturing facilities. Hitachi America, Ltd., a subsidiary of Hitachi, Ltd., markets and manufactures a broad range of electronics, comuter systems and roducts, and consumer electronics, and rovides industrial equiment and services throughout North America. For more information, visit htt:// Hitachi, Ltd., (NYSE: HIT / TSE: 6501), headquartered in Tokyo, Jaan, is a leading global electronics comany with aroximately 356,000 emloyees worldwide. Fiscal 2005 (ended March 31, 2006) consolidated sales totaled 9,464 billion yen ($80.9 billion). The comany offers a wide range of systems, roducts and services in market sectors including information systems, electronic devices, ower and industrial systems, consumer roducts, materials and financial services. For more information on Hitachi, lease visit the comany's website at htt:// 45

46 COMPRESSED AIR BEST PRACTICES / 0 6 Comressed Air Industry MANUFACTURING INDUSTRY NEWS Press Releases ENDRESS+HAUSER TO BUILD NEW MANUFACTURING FACILITY IN GREENWOOD, INDIANA The Endress+Hauser Grou will exand its locations in Greenwood, Indiana. The Endress+Hauser Flowtec Division is extending its manufacturing facilities and offices. The comany intends to invest over $17 million (USD) in Greenwood, Indiana within the next two years. With this, a substantial amount of new jobs will be created. Groundbreaking for the new facility will take lace in the first half of Aril The Endress+Hauser Flowtec comany based in Reinach, Switzerland is resonsible for flow measurement technology within the Endress+ Hauser Grou. The new exansion of its U.S. division will consist of 74,000 sq/ft for manufacturing, including a new state of the art calibration laboratory, and 16,000 sq/ft for offices and training facilities. Made in USA: The new facility will be dedicated to the manufacturing and calibration of electromagnetic flow meters; Endress+Hauser will exand its domestic offering to meters with line sizes u to 48". The new high recision and accredited calibration laboratory will be the only one of its kind in the United States. At the same time Endress+Hauser Flowtec will also remodel its resent facilities to accommodate the heavy growth of its Coriolis-, Vortex- and Ultrasonic- roduct lines. With this, Endress+Hauser is underlining its comlete commitment to the North American market and its loyal customers. Ready for the future: Products With a wide range of sensors, instruments, systems and services; Endress+Hauser covers the areas of level, flow, ressure and temerature measurement, as well as liquid analysis and recording. The range also includes the connection of field instruments to rocess control systems, as well as automation and logistics solutions. Our roducts set the standard in quality and technology. In 2004, Endress + Hauser sent 8.9 ercent of its revenues on research and develoment and logged 168 atent alications. Industries Our customers are rimarily from the chemical, etrochemical, harmaceutical, food, water & wastewater, aer, energy and oil and gas sectors. They otimize their rocess engineering rocedures with the suort from Endress+Hauser, while taking into consideration environmental rotection, safety and economic efficiency. History Endress+Hauser was founded in 1953 by Georg H. Endress and Ludwig Hauser. Since 1975, the Endress family has sole ownershi of the Grou. In 1995, Klaus Endress took over the management of the Grou from his father. For more than 50 years, the comany has develoed organically from being a secialist in level measurement to a rovider of comlete solutions for industrial measuring technology and automation, while continually breaking into new markets Endress+Hauser Flowtec is considering this resent construction as a first ste. The site develoment and the site caacity will allow for future exansion as needed. Endress+Hauser Flowtec is also serving its Central- and South American customers out of the Greenwood, Indiana lant. The Endress+Hauser Grou Endress+Hauser is a global rovider of measurement instrumentation, services and solutions for industrial rocess engineering. In 2004, the grou emloyed 6,294 associates, generating aroximately $940 million (USD) in revenues and aroximately $50 million in rofits. The family owned business comrises 71 comanies in 35 countries, managed and coordinated by a holding comany in Reinach, Switzerland. Cometent emloyees and artners guarantee quality sales and services in every art of the world. ISO certified calibration rig allows Endress+Hauser to deliver highly reliable measuring instruments with fast delivery times to our customers throughout North and South America.The large calibration rig above handles flow tubes u to 12 inches in diameter. 46

47 Comressed Air Industry MANUFACTURING / 0 6 COMPRESSED AIR BEST PRACTICES ATLAS COPCO COMPLETES ACQUISITION OF COMPANY IN HEALTHCARE SECTOR Stockholm, Sweden,August 25, 2006:Atlas Coco North America Inc. has acquired Beacon Holdings Cororation (arent comany to BeaconMedaes and Medaes), United States, from The Riverside Comany.The BeaconMedaes grou is a solutions rovider, redominantly of medical air systems and medical utility delivery systems for hositals. In 2005 revenues were arox. MSEK 720 (MEUR 77) and the oerating rofit margin arox. 7%.The urchase rice, aid in cash, was MSEK 700 (MEUR 75).The BeaconMedaes grou is headquartered in Charlotte, North Carolina, the United States and has 386 emloyees.the comany has assembly facilities and a strong resence in both the United States and Great Britain. It is a world-leading sulier of medical air equiment, including medical air comressors, vacuum systems and ieline comonents. Its roducts, for examle, suly breathing air for hositals and comressed air to drive surgical tools. BeaconMedaes becomes Atlas Coco s cometence center for medical air and medical utility delivery systems.the business is art of Atlas Coco Comressor Technique s Industrial Air division and the roducts will be sold under the brand names Atlas Coco, Medaes and BeaconMedaes. For further information lease contact: Joanna Canton, Media Relations Manager +44 (0) Atlas Coco is a world leading rovider of industrial roductivity solutions. The roducts and services range from comressed air and gas equiment, generators, construction and mining equiment, industrial tools and assembly systems, to related aftermarket and rental. In close cooeration with customers and business artners, and with more than 130 years of exerience, Atlas Coco innovates for suerior roductivity. Headquartered in Stockholm, Sweden, the Grou s global reach sans more than 150 markets. In 2005, Atlas Coco had emloyees and revenues of BSEK 53 (MEUR 5 600). Learn more at DOMNICK HUNTER S MINI DRY AIR SYSTEM PNEUDRI MiDAS, a mini dry air system, rovides lant engineers uninterruted clean dry comressed air just where they need it without the need for drying the entire comressed air system which can be both costly and totally unnecessary. PNEUDRI MiDAS contains both a high efficiency and articulate filter along with a desiccant cartridge inside a single module allowing contaminated comressed air in and clean dry air out. A 100% service can be achieved in less than 15 minutes due to the quick release to ca arrangement, which does NOT require the inlet/outlet orts to be disconnected as with traditional systems. Boasting to end re-ressurization, PNEUDRI MiDAS ensures uninterruted comressed air at all times. The unit can be laced directly after a comressor OR after a articular alication where the air is critical to the oerating rocess or end roduct. Units can be wall or canoy mounted using an otional mounting kit where sace is limited. The unit is available at a ressure dewoint of 40 F or 100 F and at flow rates of 3 to 20 scfm at 100 sig.tyical alications include: Comuter Numerical Control (CNC) Machines, Coordinate Measuring Machines, Laboratories, Lasers, Packaging Machines, Instrumentation, Processing Equiment and Conveying Machines. For more information contact domnick hunter at (800) or visit our website at

48 COMPRESSED AIR BEST PRACTICES / 0 6 Comressed Air Industry MANUFACTURING INDUSTRY NEWS Press Releases IMMEDIATE AVAILABILITY! QUICK-SHIP BLOWER PACKAGES FROM 5 TO 200 HP Kaeser Comressors, Inc. announces our new Quick-Shi ackage blower series. Kaeser now stocks a full range Com-aK Plus rotary lobe blower ackages in h.available for immediate delivery, most units can be shied in one working day. The comlete Com-aK Plus units include our otimized and rorietary tri-lobe Omega Plus rofile lus a generously sized motor, silencers, instrumentation and valves. All maintenance oints, including the automatic belt tensioning device, oil drains and filter elements, are accessible through the wide-oening canoy on the front.all ower and rocess connections are at the rear allowing multile units to be mounted side by side with no need for additional access clearance.the standard sound damening enclosure lowers tyical noise levels to 75 db(a) or less.an integral ventilation fan rovides efficient cooling, even under extreme load conditions. Need it now? Whether it s a new installation or a relacement unit, Kaeser has the solution. For more information on our Quick-Shi series, call us today or visit us at

49 Comressed Air Industry MANUFACTURING / 0 6 COMPRESSED AIR BEST PRACTICES FLUKE LAUNCHES LEM INSTRUMENTS POWER QUALITY TEST EQUIPMENT IN US MARKET EVERETT, Wash. Fluke Cororation, the world's leading sulier of test and measurement equiment, is adding LEM Instruments ower quality tools to its line of ower quality testing equiment. Designed to address a wide range of ower quality testing alications, the LEM Instrument roducts are now available from selected Fluke distributors. LH1050/1060 Power Clam Meters combine the functionality of a current clam and a ower and harmonics meter in a single handheld instrument designed to meet international safety standards (IEC 61010, CAT III 600 V rating) and ease of use. They offer a wide range of measurement caability suitable for use in installing and testing of dc ower systems, in measuring harmonics voltage and current on industrial systems, and in ower and energy otimization. The LH1050 Power Clam Meter has a suggested US list rice of $649, and the LH1060 Power Clam Meter has a suggested US list rice of $749. Analyst 2060 Power Quality Clam Meter is a handheld instrument that combines the functionality of a current clam, ower quality meter, oscilloscoe and data logger. With a comrehensive range of measurement functions, the Analyst 2060 Power Quality Clam Meter is a designed to meet international safety standards (IEC 61010, CAT IV 600 V rating) and ease of use in alications including commissioning and maintaining variable seed drives, installing and testing of dc ower systems, and measuring harmonics voltage and current on industrial systems. It features a large dislay for viewing waveforms, charts and multi-arameter measurements, enables immediate harmonics analysis with a 'live' bargrah dislay, and suorts trend measurement analysis by logging data on u to 5 arameters for 24 hours. The Analyst 2060 Power Quality Clam Meter has a suggested US list rice of $1,095. Analyst 3P Three-Phase Power Analyzer is a handheld instrument for recording and analyzing ower and energy in commercial and industrial facilities. Combining data logging with the functionality of a voltage, current and ower meter, the Analyst 3P includes 4 flexible current robes for measuring all three hases and neutral. It enables users to set u recording in seconds for NEC-required load studies, to easily view trends and recorded data with the PQLogView software included with the unit, and to generate reorts. It features an oscilloscoe function for visualizing voltage and current measurements, as well as voltage event cature and harmonic analysis functions. The Analyst 3P Three-Phase Power Analyzer has a suggested US list rice of $2,195. Memobox Power Distribution Network Analyzers are a line of ortable ower quality recorders designed for low- and medium-voltage alications including those in electric utility network environments. Memobox analyzers are caable of monitoring u to 500 arameters, and can store measurements in memory for u to 85 days. The units come with alication software designed for intuitive oeration that rovides trend diagrams, statistical summaries, reort writing and real-time data monitoring in the online mode. There are three models to choose from: Memobox 300 P analyzer is an IP65-rotected recorder that enables users to monitor the most common ower arameters including V, A, W, VA, VAR, PF, energy, flicker, voltage events and THD; Memobox 300 A analyzer includes all the features of the 300 P analyzer, as well as advanced monitoring caabilities including voltage and current harmonics, interharmonics, rile, unbalance and frequency; and the Memobox 808A analyzer is an IP50-rotected ower quality recorder that features a real-time LC dislay, five hour UPS and exanded memory caabilities. The Memobox 300 P Power Distribution Network Analyzer has a suggested US list rice of $3,995; the Memobox 300 A Power Distribution Network Analyzer has a suggested US list rice of $4,995; and the Memobox 808 A Power Distribution Network Analyzer has a suggested US list rice of $5,995. For more information on the comlete line of ower quality testing equiment available from Fluke, visit or contact Fluke Cororation, P.O. Box 9090, Everett, WA USA 98206, call (888) , fax (425) , or fluke-info@fluke.com. Fluke Cororation, which acquired LEM Instruments in June 2005, is the world leader in comact, rofessional electronic test tools. Fluke customers are technicians, engineers, electricians and metrologists who install, troubleshoot, and manage industrial electrical and electronic equiment and calibration rocesses for quality control. 49

50 COMPRESSED AIR BEST PRACTICES / 0 6 Comressed Focus Air Industry MANUFACTURING Job Oenings in the Comressed Air Industry ZORN COMPRESSOR & EQUIPMENT SERVICE MECHANICS NEEDED: (TWO POSITIONS) Wisconsin s leading indeendent distributor of comressed air equiment is seeking exerienced service technicians with mechanical, electrical, and refrigeration skills to service industrial air comressors in Green Bay and Southeastern Wisconsin. Zorn Comressor & Equiment is a rivately owned comany that has been serving Wisconsin industry for more than 40 years. Benefits include comany service truck, uniforms, health insurance, 401k lan, and a very cometitive wage rate. Please send resume via fax to , us at jobs@zorn-air.com or call us at Scales Industrial Technologies, An Emloyee Owned Comany and growing leader in the comressed air industry is looking to add qualified energetic self-starters to our team. We are resently interviewing for Field Service Technicians, Sho Technicians, Machinists and Sales Engineers. We offer a comrehensive benefits ackage including; comany stock, 401K, medical and education. Send resume to niff@scalesair.com West Paterson, NJ Carle Place, NY Sharon Hill, PA Meriden, CT Worcester, MA

51 ADVANCED SOLUTIONS FOR YOUR COMPRESSED AIR CHALLENGES The BEKO range of reliable erformance roducts includes all asects of economical, safe and ecologically resonsible comressed air use. With their unique and diverse caabilities, all of the roduct families meet the demands of tomorrow s advancements today, from individual comonents right u to those of comlete large-scale systems. Being that every system, no matter how large or small, is made u of individual comonents, only comonents that are designed to work with each other, and are suited to rigorous alications and conditions can fulfill their erformance exectations in a reliable and environmentally friendly way. BEKO does more than manufacture henomenal roducts, we are a comlete solutions rovider. Ranging from analysis of the roblem, to secification, installation suort, maintenance resolutions and comrehensive customer service, the BEKO knowhow for comressed air use is customer oriented with a global focus. CONDENSATE TECHNOLOGY COMPRESSED AIR TREATMENT MEASUREMENT TECHNOLOGY PROCESS TECHNOLOGY Condensate Discharge Condensate Treatment Filtration Drying Instrumentation Dee Cooling BEKOMAT the convincing concet for condensate discharge BEKOSPLIT ÖWAMAT QWIK-PURE for the safe, reliable treatment of all condensate tyes CLEARPOINT rocess reliable and flow otimized filters and water searators for comressed air and technical gases DRYPOINT AC DRYPOINT M DRYPOINT RA adsortion, membrane and refrigeration dryer lines A full range of roducts for leak detection, as well as flow meters and dew oint meters for air quality control. BEKOBLIZZ otimized cooling rocess with dry, dee cooled comressed air BEKO TECHNOLOGIES CORP 236 Raceway Drive Suite 1 Mooresville, NC USA Phone +1 (800) Fax +1 (704) beko@bekousa.com

52 At Kaeser, our tradition of saving energy goes back generations. We didn t start engineering the world s most energyefficient comressors when it became the in thing to do. And now when it matters more than ever our eight decades of design innovation and fine-tuning translate into systems that are u to 25% more energy-efficient than the cometition. That adds u to a lot of valuable energy and bottom-line dollar savings, too. Enough, in fact, to ay for your comressed air equiment many times over. With age comes exerience. So, when you re comaring comressor erformance and reliability, it ays to remember the lengths we ve gone to for generations. info.usa@kaeser.com Kaeser Comressors, Inc., P.O. Box 946, Fredericksburg, VA USA (800) Built for a lifetime is a trademark of Kaeser Comressors, Inc Kaeser Comressors, Inc.