Guaranteed constant pressure differential protects the membrane bundle from damaging pressure surges. Gain control. Reduce power costs. Save a bundle.

Transcription

1 Corrugated Packaging J A N U A R Y Paer Mill Saves Water TM

2 ISO AIR QUALITY TO CLASS FLOWS FROM 0.29 to SCFM PRESSURES TO 200 PSIG MODULAR DESIGN FREES UP FLOOR SPACE OIL FREE AIR WORLDWIDE DISTRIBUTION Hankison SweeSaver TM comressed air dryers feature digital urge control to save energy and rotect membrane fibers. SweeSaver s exclusive design can align urge flow with air demand for recise dew oint control with zero waste. Guaranteed constant ressure differential rotects the membrane bundle from damaging ressure surges. Gain control. Reduce ower costs. Save a bundle.

3 Conserve Energy and Save Money with Variable Seed Drive Comressors When a major California winemaker exanded its grae squeezing oeration, the ability to automatically control the variable demand of comressed air rovided energy savings that heled the roject ay for itself faster. Atlas Coco Variable Seed Drive (VSD) air comressors recisely match the outut of comressed air to your air system's fluctuating demand. Atlas Coco has an established record of success creating solutions for our customers whose demand for comressed air varies. Our VSD comressors offer the most advanced technology and the greatest energy efficiency on the market today. More than 90% of all comressor alications are high otential candidates for VSD comressors, and we work with our customers and their engineers to design and imlement energy efficient solutions for ugrades and new construction. If you want to ay only for the comressed air you need, lease contact Atlas Coco at or us at: comressors.vsd@us.atlascoco.com

4 COMPRESSED AIR BEST PRACTICES 0 1 / 0 7 FOCUS INDUSTRY FEATURES CPR Saves Water in a Paer Mill 15 By Comressed Air Best Practices Paer Mill in Canada Imroves Comressed 20 Air Quality and Comressor Cooling By Graham Whitmore Focus Industry Variable Seed Drive Air Comressor Triggers 23 Energy Rebate at Container Plant By Scott A. Williams Membrane Dryers at Paer & Pul Facilities 27 By Comressed Air Best Practices ALTERNATIVE ENERGY FEATURE High Pressure Air Comressors 29 Oen Door for Methane Biogas By Paul Green

5

6 COMPRESSED AIR BEST PRACTICES 0 1 / 0 7 COMPRESSED AIR INDUSTRY ARTICLES Comressed Air Industry 10 From the Editor 8 Letter to the Editor 9 Multi-Branding at Atlas Coco 10 Pneu-Logic Cororation 32 Arrow Dryers by McIntire 36 VFD Saves Energy 40 For Tractor Manufacturer By Comressed Air Best Practices Industry News 42 Job Market

7 Focus Industry 0 1 / 0 7 COMPRESSED AIR BEST PRACTICES 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:

8 COMPRESSED AIR BEST PRACTICES 0 1 / 0 7 FROM THE EDITOR Saving Water in Challenging Ambients Comressed Air Industry The last two editions, of Comressed Air Best Practices Magazine, have dealt with two industries, which must manage aggressive ambient conditions; cement and ul & aer.the challenge resented by dusty and hot ambient air, to comressed air systems, is significant. The comressed air industry has resonded to these two editions with some wonderful examles of how to meet these high ambient challenges and save significant amounts of water. Most aer & ul lants oerate under the imression that they must use water-cooled air comressors, due to the amount of aer dust in the ambient air.this month s edition shows how a aer mill and a corrugated container lant were able to use air-cooled air comressors and thereby save hundreds of thousands of gallons of water.the air-cooled air comressors, combined with investments in air ducting, have allowed these facilities to no longer use water in their comressor room. Our industry is also involved with renewable energy. Motivair Cororation writes of an enormous aer mill, which installed a closed-loo cooler to take advantage of the existing water in their on-site ond. ComAir discusses the growing oortunities in methane biogas and how high ressure comressors can make this form of renewable energy commercially viable. Imroving the bottom line of the cororation, while taking environmentally-friendly actions, is illustrated in these articles. Plant engineers and lant managers often must take risks, to break old aradigms and beliefs (like the water-cooled vs aircooled aradigm).when they do, they reward their comanies with rofits and the world with a better environment. My hat is off to the lant engineers and lant managers bold enough to take these stes. ROD SMITH COMPRESSED AIR BEST PRACTICES MAGAZINE Advertising & Editorial: Subscritions & Administration: A Publication of: Rod Smith rod@airbestractices.com Tel: Patricia Smith atricia@airbestractices.com Tel: Smith Onandia Communications L.L.C. 161 Clubhouse Circle Fairhoe, AL 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 POST- MASTER: Send address changes to Comressed Air Best Practices, 161 Clubhouse Circle, Fairhoe, AL Printed in U.S.A. 8

9 LETTER TO THE EDITOR CLASS ZERO Regarding the article titled Comressed Air Systems for ISO , Class-Zero, Oil-Free Air in the October 2006 edition of your magazine, I would like to give your readers some additional information, and erhas clarify some of the statements made in the article. The authors state that a modern lubricated comressor, without any filters, has an outut of 3 m of oil in the air suly. Today s modern coalescing filters are designed to remove liquid oil aerosols from comressed air, and tyically have oil removal efficiencies of 99.97% or higher. If we aly a single filter with an efficiency of 99.97% to the examle above, where there are 3 m of residual oil in the comressed air suly, then the oil content downstream of the filter will be reduced to m, or 0.9 arts er billion. If a second coalescing filter is installed in series with the first filter, then the residual oil content is below the level of detectability, at a theoretical 0.27 arts er trillion. This is many orders of magnitude cleaner than the cleanliness level stated in the article of 0.01 m using two filters. Later in the article, the authors mention that the urity class for oil in comressed air, as defined by the 1991 version of ISO did not include oil vaors, when in fact the standard did include vaors as well as aerosols and liquid oil drolets. Section of the 1991 standard does state that oil vaor content can be disregarded when the air is used for non-critical alications, but it must be measured and reorted according to section 6.3. The authors are correct in saying that the 2001 revision of ISO also grous all three tyes (liquids, aerosols, and vaors) into the classification for total oil content. Finally, the statement that atmosheric oil that is drawn in at the comressor intake is almost comletely washed away by the condensate in the intercooler and aftercooler, resulting in ure oil-free air for your rocess could lead users of oil-free comressors to disregard the effects of ambient air contaminant ingestion. In many cases oil-free comressors are used in food rearation alications, or when comressing air for contact with food, beverage, or harmaceutical ackaging. Contaminants, esecially vaors that are drawn into the comressor intake are almost always detectable at the outlet of the comressor, and users of any tye of air comressor should be aware of the otential for serious consequences due to oor air inlet quality. DAN RYAN ENGINEERING MANAGER FILTRATION FILTRATION AND SEPARATION DIVISION PARKER HANNIFIN CORPORATION COMPRESSORS FOR INDUSTRY BAUER MODEL B Stage Air Comressor HP SCFM PSIG 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 COMPRESSORS Inc Azalea Garden Road Norfolk, Virginia Tel: (757) Fax: (757) sls@bauercom.com BAUER COMPRESSORS, INC. is registered to ISO

10 COMPRESSED AIR BEST PRACTICES 0 1 / 0 7 Comressed Air Industry ATLAS COPCO: BRANDS WHICH ARE Comressed Air Best Practices interviewed the following executives of Atlas Coco: Ronnie Leten, President, Atlas Coco Comressor Technique Business Area Paul Hense, President, Atlas Coco Comressors LLC (USA) Herman Matthyssen, Vice President of Multi-Branding, Atlas Coco Comressor Technique We only buy. comanies we know we can grow. RONNIE LETEN, PRESIDENT, ATLAS COPCO COMPRESSOR TECHNIQUE Comressed Air Best Practices: Good morning! What does First in Mind, First in Choice mean? Good morning.this hrase reresents the vision for all the comressed air roduct brands within the Atlas Coco Comressor Technique Business Area. The vision for all brands is to delight their articular customers with a strong value roosition, which makes the brand First in Mind, First in Choice. How do you segment customers by brand? Each brand has a long history of delighting secific customer segments.we work hard at clearly defining and understanding the customers served by each articular brand.these are the ideal customers of each brand.we send countless hours working to deeen our understanding of who our customers are and what their needs are.we segment customers into three grous: 1. Premium roductivity and innovation 2. Value cost effective 3. Price Next to that, we also have a market & geograhy-secific segmentation of course. Can you give an examle of a remium brand? Absolutely.The Atlas Coco brand name reresents our remium roduct and service offering to comressed air users. Over one-third ( 1 3) of the global market is looking for the highest quality and technology they can find to suort their requirements for comressed air.these users understand the imortance of reliably receiving the highest quality comressed air at the most efficient energy cost. The Atlas Coco brand is sold world-wide to suort this demand. 10

11 Comressed Air Industry COMPRESSED AIR 0 1 / 0 7 BEST PRACTICES FIRST IN MIND, FIRST IN CHOICE COMPANY PROFILE What is an examle of a Value/Cost Effective brand? There is another large segment of the market which will sacrifice some remium features and designs, on their air comressor, in order to reduce the caital requirements of the roject. They require a high quality roduct which roduces reliable comressed air and which is energy efficient. Examles of brands we own, addressing this customer segment, are Worthington Creyssensac, Grassair and Chicago Pneumatic here in the U.S. Does Atlas Coco have a Price brand? No.We believe that a ure Price brand does not offer a solution for our customers. It also does not fit with our comany s hilosohy of commitment to quality. Customers only focusing on rice, focus on urchasing disosable roducts.they do not lace any value on technology, roduct features, system reliability, otimum logistics or rofessional aftermarket services. Furthermore they tend to switch brands easily, which makes it imossible to be First in Choice Ronnie Leten, President, Atlas Coco Comressor Technique Ronnie Leten is the President of Atlas Coco s Comressor Technique business area. Mr. Leten joined Atlas Coco in 1985 and has held various oerations and manufacturing ositions within Comressor Technique. Prior to his current osition, he was President of the Industrial Air and Airtec divisions. Comressor Technique, headquartered in Belgium, is Atlas Coco s largest business area. It consists of five divisions in the following roduct areas: industrial comressors, comressed air treatment roducts, ortable comressors and generators, gas and rocess comressors, as well as secialty rental. 11

12 COMPRESSED AIR BEST PRACTICES 0 1 / 0 7 ATLAS COPCO Comany Profile Comressed Air Industry Can you give an examle of what is meant by Market or Geograhy- Secific Brand segmentation? Mauguiere in France is a good examle and goes back to the origins of our multi-branding strategy in the late 1970 s. Mauguiere Comressor had a long history in the rofessional and construction aftermarket in France and had a large installed base. The comany, however, was losing market share when we bought it in 1976.We reinvigorated the Herman Matthyssen, Vice President of Multi-Branding, brand and it now commands Atlas Coco Comressor Technique a strong market share in the French rofessional and industrial market. Mauguiere is a brand whose objective it is to delight small and medium-size customers in the French market. Worthington Creyssensac is another examle.we acquired Worthington Creyssensac, in 1993, as a comany with a solid resence and installed base in southern Euroe, but which was losing market share.we knew we could grow the Worthington Creyssensac brand in Euroe if we injected new roduct develoment and imroved the sales & service network.today,worthington Creyssensac has grown significantly and is also sold in the U.K. and in Northern Euroe.We consider Worthington Creyssensac to be a Euroean-market brand. As it takes many years and a lot of investment to introduce a new brand to a new geograhy, we refer to use both organic growth and make rudent acquisitions, wherever the oortunity is available. Is the acquisition of Pneumatech a Market & Geograhy Secific brand acquisition? Yes. Pneumatech reresents a strong brand of comressed air treatment roducts in North America and in China.We are sure we will continue to grow the Pneumatech brand in these markets.the rime focus of Pneumatech is to rovide the markets in the USA and Asia with state-of-the-art air treatment roducts. The Pneumatech manufacturing facility in Wisconsin also rovides us with a U.S. manufacturing center for desiccant air dryers and roducts requiring local certifications, which can suly all brands, active in the defined territory. 12

13 Comressed Air Industry 0 1 / 0 7 COMPRESSED AIR BEST PRACTICES SUBSCRIBE NOW! Atlas Coco. is recognized, throughout our organization, as our Foundation Brand. HERMAN MATTHYSSEN What is your manufacturing strategy behind the brands? Manufacturing centers are brand neutral and have to suort the branding strategy. What really counts is that we are caable of otimizing synergies amongst brands, and that we create value for our customers, our comany and other stakeholders.this strategy is very successful.the Ceccato comressor factory in Italy now called the Product Comany Brendola, for examle, manufactures five times what it did before they were acquired in the 1990 s. The dignity of the brands is ensured by roviding the customers with new roducts on a regular basis, which are differentiated to meet their different value requirements. Our roduct comanies make this ossible.we infuse the brands we acquire with new roducts on a regular basis and we invest in their ability to market the roduct and create brand awareness.the result has been the growth of every secific brand, as their ability to otimally meet the differentiated customer requirements has been imroved. Please elaborate on roduct differentiation We mentioned we work very hard to clearly understand and segment our customers. This means we must rovide them with different roducts to meet their needs. We consider comressor elements, for examle, to be a core technology within Atlas Coco Comressor Technique. Our manufacturing centers are caable of designing and manufacturing two to three differentiated comressor elements of the same size, to meet the different customer needs of our brands.all asects of our roducts, from comressor elements, coolers, integrated air treatment, and intake valves are differentiated between the brands to delight the customer segment being served. Where does the recent Beacon Medaes acquisition fit in? 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: Acquisitions we make must fall within our ability to serve a secific geograhy or customer segment in a market.the Beacon Medaes acquisition greatly increases our ability to serve the hosital market. Beacon Medaes is a cometence center and in this case we have acquired knowledge of a market segment. Beacon Medaes will oerate as a searate business unit worldwide. Street: City: State (Province): Country: Zi Code: Phone: Fax: 13

14 COMPRESSED AIR BEST PRACTICES 0 1 / 0 7 ATLAS COPCO Comany Profile Comressed Air Industry Multi-branding aears to be retty comlex! Herman and I (Ronnie Leten) have had countless discussions on how to manage brands. We also admit to having made some mistakes along the way. It is not a simle task.we are today able to say that the strategy has been very successful for our customers, emloyees, and shareholders. Multi-branding has allowed us to serve more customers by roviding them with a differentiated value roosition, both with roducts and services. By doing so, we are able to establish a long-term business relationshi with more customers.this has translated itself into rofitable organic growth for both existing and acquired brands. The dignity. of the brands is ensured with differentiation. PAUL HENSE What does the future look like in North America? We will continue to execute our multibranding strategy.we want to continue being First in Mind, First in Choice for the remium segment of the market with the Atlas Coco brand, and with the Multi-brands for all other segments. Our decisions will continue to reinforce our strategy to also be a market leader in the value/cost effective market segment in North America. Thank you ATLAS COPCO for sharing your insights. For more information lease contact: For US Customers: Atlas Coco Comressors LLC info@atlascoco.comressors-usa.com For Canadian Customers: Atlas Coco Comressors Canada comressors.canada@ca.atlascoco.com Innovative technologies Made in Germany! drukose 1+2 drukose 3 drukomat 15 drukomat 61 drukose (3 models) caacities u to 130 cfm comact design safe floor and wall installation 3 connections for condensate inlet Testglas box for instruction-book Wortmann has been, for more than 30 years, a leading oil-water searator manufacturer in Germany and Euroe. In fact, we were the first manufacturer of oil-water searators for comressed air. Wortmann is now looking for regional master distributors for the USA and Canada. Are you interested in selling leading technologies in North America? Send us an to: Mr. Markus Hefter, info@drukomat.de drukomat (6 models) caacities u to 3600 cfm box for instruction-book Testset - glas and oil-test aer Imortant: only one tye of coal-filter suitable for all 6 models - lower stockkeeing costs - easy handling We will deliver directly to you, from door-to-door! D.D.P. excl. duties and taxes Wortmann Druckluft GmbH Hautstr Fröndenberg, Germany Phone: / Fax: / info@drukomat.de 14

15 Focus Industry COMPRESSED AIR 0 1 / 0 7 BEST PRACTICES SAVING Water IN A PAPER MILL Comressed Air Best Practices interviewed the following emloyees of Comressor & Pum Reair Services (CPR) Inc. Martha Kinate, General Manager Jodie Blumreich, Oerations Manager Jim Kinate, President Comressed Air Best Practices: How did you hel a aer mill reduce water consumtion? Like many of its kind in Wisconsin, this aer mill is located on a river and emloys over 4,000 eole.the mill has been on the EPA s Deartment of Natural Resources watch-list for water consumtion for many years.the oerations eole are always looking for ways to reduce water consumtion and increase efficiency.we were asked to visit the facility and roose ways to address three issues: 1. Water-cooled air comressors were consuming million gallons of water er year 2. Yearly maintenance and rebuild costs for the air comressors was $550, Moisture was resent in the comressed air lines during cold winter days Kaeser Air-Cooled Rotary Screw Comressor at Paer Mill 4. Imrove the efficiency of the system 15

16 COMPRESSED AIR BEST PRACTICES 0 1 / 0 7 SAVING WATER IN A PAPER MILL Focus Industry PAPER MILL BEST PRACTICE ACTIONS 1. Relace the water-cooled iston comressors with air-cooled rotary screw comressors secifically designed for high ambient conditions 2. Install ducting to bring fresh ambient air into the air comressors and to duct heat uwards and out of the comressor room 3. Install blower urge desiccant dryers and stainless steel ie which assures the facility with -40 F dew oints and dry air throughout the facility 4. Install two 15,000 gallon horizontal receiver tanks. The first tank is a wet tank at the comressor outlet. We searate a tremendous amount of moisture in this tank and imrove the efficiency of the desiccant dryers. The second tank is installed at the dryer outlet and maintains otimal air ressure 5. Install a flow controller which sulies 82 sig ressure to the lant 6. Quarterly-interval maintenance contract with 24/7 on-call caabilities to manage high aer-dust ambient conditions BEST PRACTICE RESULTS 1. Water savings of 1.5 million gallons er day and million gallons er year 2. Maintenance cost reduction of $470,000 er year 3. Clean, dry air throughout the mill and no instrumentation roblems What did your analysis of their system find? The mill was using eighteen water-cooled iston air comressors.they averaged forty years of age and sizes ranging from 150 to 200 horseower.these old workhorses required yearly rebuilds and scheduled maintenance with costs totaling $550,000.They also generated a tremendous amount of heat. When the heat being generated was combined with a hot summer day, ambient conditions in the comressor room could reach 120 F.The water requirement to kee these comressors cooled was 1.5 million gallons er day. The oerations management was under the imression that they had to use water-cooled air comressors due to the high ambient temerature conditions. The mill was drying the air with refrigerated air dryers. The dryers had been sized for 100 F ambient conditions and were comletely overloaded.the result was elevated dew oints and moisture resence in the downstream air lines.this caused roblems, in articular, with instrumentation located around the mill. The other imortant factor the analysis discovered was that their lant air ressure requirement was sig. They were, however, delivering comressed air at 100 sig. Aren t water-cooled comressors the only otion for 120 F ambient conditions? Many ul and aer mills have the misercetion that they have to use water-cooled machines due to their high ambient conditions.this is false and an area of oortunity for them.we reviewed the following recommendations with them (see sidebar on left). How have the results turned out? Very well.the facility is so leased with the results that we have used them as a reference for other aer & ul mills.this rocess has since been relicated with Kaeser comressors at two other facilities. 16

17 Focus Industry 0 1 / 0 7 COMPRESSED AIR BEST PRACTICES When was CPR started? Comressor & Pum Reair Services was established in DePere, Wisconsin in 1984 as a service comany for industrial ums and air comressors. In 1986 we exanded into mechanical contracting and secialized in industrial air iing and municial sewage treatment.the sales division sold mostly ums to the industrial and municial markets. In 1988, the sales deartment exanded to include industrial air comressors. KAESER comressors was chosen as our main comressor line and we have since laced over 2000 units in our territory. We are the sole distributor for KAESER in Wisconsin, Minnesota, North Dakota and Michigan s Uer Penninsula. Air-cooled Comressors Provided Water Savings of 1.5 million gallons er day How does CPR cover so much geograhy? We have regional sales eole in the field and have a large grou of dealers. Dealers cover secific markets. Our regional sales eole suort their efforts, articularly with larger installations.the strength of dealers is with the smaller installations in their area. How does inside sales suort outside sales? Inside sales generates leads for outside sales eole. This makes our outside eole much more efficient with their time. Our inside sales and marketing eole execute the following functions: 1. Call otential customers to set u aointments. We now get referrals from over 2000 installed air comressors. 2. Multile direct mail efforts go out every year. Follow-u hone calls are made to generate sales aointments. Jim Kinate, Martha Kinate, and Jodie Blumreich of CPR Inc. 3. Follow-u mailings to our customer base. We want to make sure they are satisfied customers and kee our ulse on new oortunities. 4. ers are sent to customers or rosective customers. We find an increasing ercentage of eole refer an to other forms of contact. 17

18 COMPRESSED AIR BEST PRACTICES 0 1 / 0 7 Focus Industry SAVING WATER IN A PAPER MILL How does your sales force hel your comany be so efficient? We have suorted the sales force with technology from day one. Each outside erson carries hones which take hotos and can receive s direct from our comuter network. They also have latos.they use the technology to increase their and our over-all efficiency. 1. If a customer s a sales erson he can see it on his hone and handle it right away. If he needs to forward it to inside sales or accounting it s done right away. Accounting can then resond to the customer right away. Faster resonse time for customers is the result. 2. Sales and service eole are required to generate service work. They use their cameras on their hones to hotograh name late data on air comressors. They then the hoto to technical service so that the aroriate arts can be identified and the customer can be sent a service roosal. The hotos have eliminated countless back and forth hone calls with the customer needed to figure out what arts are needed. The result again has been increased efficiencies for our customers and our comany. 3. Installation hotos are taken in advance by the sales eole. When our installers arrive at a site, they arrive reared to deal with every situation because they have seen hotos of the installation beforehand. There are no delays or extra tris which again make the whole rocess more efficient for our customers and ourselves. 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: CPR Headquarters De Pere, Wisconsin CPR Facility Minneaolis Area Comany Name: Street: City: State (Province): Zi Code: Country: Phone: 18

19 Focus Industry 0 1 / 0 7 COMPRESSED AIR BEST PRACTICES How does CPR use technology in assessing your customer s comressed air needs? Comressor Pum & Reair (CPR) secializes in evaluating systems.we utilize Kaeser s excellent Air Demand Analysis rocess in many alications.an analysis will often involve: Trending the system by installing kw meters and flow meters Provide a customized reort with a situation analysis and recommendation summary Suly a 3-D layout drawing of the recommendation What other factors have been imortant to your growth? Selling quality roducts is of utmost imortance to our growth and success. We sell the highest quality equiment, like Kaeser comressors. Our hilosohy is to try to make every business transaction beneficial to our customers as well as our comany. Quality roduct lines seak for themselves.when you combine quality roducts with a good sales & service organization, good things haen. Thank you CPR for your insights. Selling quality. roducts is of utmost imortance to our growth and success CPR Service Trucks 19

20 COMPRESSED AIR BEST PRACTICES 0 1 / 0 7 Focus Industry PAPER MILL IN CANADA IMPROVES QUALITY AND COMPRESSOR COOLING BY GRAHAM WHITMORE This article reviews two major rocesses in aer mills: comressed air quality and air comressor cooling.the central air comressor room was exanded and relocated at the largest rivately owned aer mill in Canada.The comressor sace was required by a lant exansion, which would occuy the original comressor sace for increased roduction. The existing, oen draft cooling towers for the centrifugal air comressors were aging, and required a major caital exense for relocation, reair & re-iing. An additional centrifugal air comressor was installed and a central 12,000 scfm refrigeration dryer was added to suly the entire lant with dry, oil-free air.the dryer was required to be a redundant, cycling dryer so that the mill could oerate round the clock, while minimizing ower consumtion and the risk of downtime. Motivair Large-Caacity Cycling Refrigerated Dryer During the comressor & dryer re-installation discussions, it became aarent that a better comressor cooling solution was ossible, and within the constraints of the original roject time frame.the mill ond water never exceeded 72 F in the summer, but was not considered clean enough for the air comressors.the roject roosed using the mill ond water with a late & frame cooling system to suly clean water in a closed loo to the air comressors.this avoided the exense of tower refurbishing & relocation, while also eliminating the evaoration losses & make-u, along with the associated water treatment and maintenance. A strategic decision was made by the mill to change direction, and roceed with the new roosed closed-loo cooling system in arallel with the new comressor & dryer installation. Large Caacity Dryer The large caacity refrigerated dryer (12,000 scfm) was designed to satisfy the secific mill requirements for reliability, redundancy & energy efficiency. The shell & tube heat exchangers & integrated searator were designed for a maximum ressure dro of only 2.0 PSI at 12,000 SCFM.The maximum oerating air comressor shaft BHP was around 2,500.Therefore a design ressure dro of 2.0 PSI was intended to reduce the air comressor ower required by 50 kw/h comared to a traditional air dryer 5.0 PSI ressure dro. 20

21 Focus Industry 0 1 / 0 7 COMPRESSED AIR BEST PRACTICES COMPRESSED AIR The refrigeration was sulied by four semi-hermetic comressors with cylinder unloading, installed in four comletely indeendent arallel refrigeration circuits. This design allows any circuit to be off-line for service or reair, while the others remain in full oeration. Searate ower disconnects for each comressor and glycol um enable the oerator to erform any maintenance safely, while the lant dry air suly is uninterruted. The dryer is a cycling design, which requires the refrigeration comressors to cool a circulating mass of glycol solution, which in turn cools the air in a searate heat exchanger. 2 searate glycol ums, with auto change & alarm insure a continuous glycol flow.the refrigeration comressors sequentially unload, and cycle off, based on the alied comressed air load at any time.they automatically absorb only the minimum ower required to meet the load.the PLC controller automatically rotates the comressor & um sequence, and revents short-cycling.the resulting dew oint is a constant F, regardless of load changes. The airborne condensate is searated from the air stream in a 2-stage ultrahigh efficiency stainless steel searator which guarantees >99.9% searation efficiency from zero to 100% load.this is esecially imortant in large caacity dryers, which can exerience very low airflow between shifts, or in off-eak eriods, weekends, etc. The accumulated condensate is discharged via 3 x arallel neumatically-owered drain valves.any valve can be isolated and removed while the others remain in oeration. Since start-u in 2003, the dryer has never been inoerative, and has imroved roductivity at the mill through imroved comressed air quality. Comressor Cooling System 21

22 COMPRESSED AIR BEST PRACTICES 0 1 / 0 7 Focus Industry PAPER MILL IN CANADA IMPROVES COMPRESSED AIR QUALITY AND COMPRESSOR COOLING Comressor Cooling System The mill s air comressor cooling system was designed to cool the existing centrifugal air comressors and the new Motivair water-cooled 12,000 SCFM refrigeration air dryer, lus lanned comressor growth for the next several years.the design heat load was established at 18,300,000 Btu/h, cooling 1,475 GPM from 110 F to 85 F, using 2,439 GPM of mill ond water at 72 F, and leaving at 87 F. Motivair designed and built a single skid-mounted ackage, which consisted of a stainless steel late & frame heat exchanger, dulex 75 HP circulation ums with VFD, for the closed loo circuit, filtration of the mill ond water, and all associated 8" rocess control valves and iing in 316 stainless steel. The entire ackage measured 20 feet x 10 feet wide x 9 feet high and weighed aroximately 20,000 Lbs.The cooling skid was easily installed inside the building, and the sace occuied was a fraction of that required for the original outdoor cooling towers & ums.the closed loo water temerature was comarable (85 F) to an otimized evaorative cooling tower, but without the evaoration losses and water treatment required by a tower, in a smaller footrint, and at a cometitive cost.the construction (all 316 stainless steel) was comatible with the tyical airborne ollutants found in a aer mill. The combined equiment cost of the Motivair 12,000 SCFM refrigeration dryer and the new closed loo cooling system was aroximately US$350,000, lus installation.the entire cost will be recovered through increased roductivity, by eliminating unscheduled downtime, and reduced system maintenance. For more information lease contact Mr. Graham Whitmore, Motivair Cororation, gwhitmore@motivaircor.com, tel: , The roject roosed using the. mill ond water with a late & frame cooling system to suly clean water in a closed loo to the air comressors. 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:

23 V A R I A B L E S P E E D D R I V E A I R C O M P R E S S O R ENERGY REBATE AT CONTAINER PLANT BY SCOTT A. WILLIAMS T R I G G E R S You ve likely witnessed this scene at a birthday or holiday celebration: A gift is unwraed, a much-anticiated toy is revealed, and a child lays haily with the cardboard box in which the toy was ackaged. Beyond its treasured role as a layhouse or fort, corrugated cardboard is the ideal material for ackaging. It s easy to understand why. Corrugated is both functional and versatile in alications ranging from secialized industrial shiing containers to high-end consumer goods ackages. In fact, corrugated is the most widely used ackaging material. Packaging Cororation of America (PCA) Packaging Cororation of America (PCA) focuses squarely on corrugated ackaging at its 66 manufacturing and converting facilities.at PCA s lant in Northamton, Massachusetts, between 3,200 and 4,000 tons of corrugated ackaging are shied each month to customers from Maine to New Jersey who ackage roducts ranging from food roducts to sorting goods to stuffed animals. The manufacture of corrugated roducts goes on non-sto at PCA Northamton. The fabricating line, where corrugated boxes are made from blanks, runs 24 hours a day, according to Tom Dougherty, Production Manager at PCA Northamton. The corrugators, where blanks are made, run two shifts of either 8 or 10 hours a day, deending on demand. 23

24 COMPRESSED AIR BEST PRACTICES 0 1 / 0 7 Focus Industry VARIABLE SPEED DRIVE AIR COMPRESSOR TRIGGERS ENERGY One resource that is crucial to the lant s ongoing oeration is a reliable suly of comressed air. Maintenance Suervisor Peter Cincotta exlains. Without. comressed air, we d basically shut down. We have neumatic motors that oen and close machines.air owers the diahragm ums that move wastewater and starch from the corrugators. Reverse-air cleaning filters remove starch on air bags.there are air-driven motors that mix ink in the rinting rocess, and our rinting lates and rolls are loaded using air. We have hundreds of feet of conveyors that are driven by electric motors, but the bladder bags that raise and lower the zone carriages are neumatic. So is the braking system.the straing oeration at the end of the line has a dual laten system to raise and lower the stra around the track, adjust the tension and seal it.that s neumatic, too.without comressed air, we d basically shut down. In 2004, a combination of air starvation roblems and rising energy costs convinced Dougherty and his team that it was time to ugrade the lant s air comressor system.working with Gerry Carney, Sales Reresentative at Atlas Coco s New England Comressor Center, a new system was configured. Variable Seed Drive Comressor Triggers Energy Incentive Rebate Carney describes the installation. The system uses two Atlas Coco comressors. The lead unit is a 75 h GA55C-125AFF with built-in dryer.the trim unit is a 75 h GA55VSD AFF with built-in dryer and Variable Seed Drive.The installation involved comleting the lant s air iing to form a closed loo system.we also installed a 1,550 gallon vertical storage tank equied with a demand controller to regulate air ressure in the header line.we store comressed air at 120 si, and a regulating valve downstream of the tank releases air to the lant at 85 si.with the larger storage tank, demand controller, and comleted iing line, the air starvation roblem was eliminated. 24

25 Focus Industry 0 1 / 0 7 COMPRESSED AIR BEST PRACTICES REBATE AT CONTAINER PLANT Dougherty exlains that the system s energy-saving design qualified for an Energy Incentive Rebate from Massachusetts Electric Comany. That rebate lowered the cost of the roject and shortened the ay-back eriod. One key to qualifying for a rebate was the Atlas Coco Variable Seed Drive comressor, which automatically varies the roduction of comressed air to recisely match the demand.the storage tank rovided another rebate oortunity since it is equied with a regulator valve. (PCA Northamton also articiated in a lighting rebate rogram to further cut its energy costs.) With the new comressors in oeration, our ower costs went down significantly, says Dougherty. Comaring 2005 to 2004, we saved 16,000 kw er month, just from the comressor ugrade.that droed the total electrical consumtion in our lant by 4.3% to 384,000 kw er month. Here s another way to look at it: we roduced more in 2005 but we used less electricity because of the new comressors. Reduce Water Use by 3,500 Gallons er Day In addition to energy cost savings, the new comressors enabled PCA Northamton to cut the cost of buying and disosing of water. Two of our old comressors were water cooled, Cincotta exlains. Getting rid of the water cooled units saved 3,500 gallons of water er day.that s over 100,000 gallons of water er month! Of course we had to ay for all that water, and then it went right down the drain increasing our monthly sewage charge.we worked on some ways to utilize the warmed water, but outut temeratures weren t consistent enough to make it worth the effort.the air-cooled air comressor units eliminate these water exenses comletely. Packaging Cororation of America (PCA) roduces a wide variety of corrugated ackaging roducts, including conventional shiing containers used to rotect and transort manufactured goods, and multi-color boxes and dislays with strong visual aeal that hel to merchandise ackaged roducts in retail locations. PCA Northamton, which also rovides in-house services including ackaging design, grahics, rinting, gluing, and die cutting, is one of 66 PCA oerations across America. 25

26 COMPRESSED AIR BEST PRACTICES 0 1 / 0 7 Focus Industry VARIABLE SPEED DRIVE AIR COMPRESSOR TRIGGERS ENERGY REBATE AT CONTAINER PLANT Of course heat remains a byroduct of air comression (no one can change the laws of hysics), so the new comressors are situated to take advantage of latent heat outut during cold weather. We ut the comressors right beside a door where we receive roll stock each day, says Cincotta. During the 20 minutes the truck takes to unload, cold air sees in around the dock seal. The heat from the comressor hels kee that area a bit warmer when unloading. When the heat is not needed, such as in warm weather, an overhead exhaust fan blows it outside. With the air comressors in service for more than a year, Dougherty is leased with their erformance, reliability and efficiency. We haven t had any issues related to an outage of air, he exlains. They run really great and use less energy.what more can you say? For more information lease contact: For US Customers: Atlas Coco Comressors LLC info@atlascoco.comressors-usa.com For Canadian Customers: Atlas Coco Comressors Canada comressors.canada@ca.atlascoco.com 26

27 Focus Industry COMPRESSED AIR 0 1 / 0 7 BEST PRACTICES Membrane Dryers AT PAPER & PULP FACILITIES BY COMPRESSED AIR BEST PRACTICES Paer and ul mills often have moisture in the comressed air. It causes the instrumentation oerating the machinery, to malfunction and creates roduct defects. Plant engineers do not have simle solutions at hand, and like with most situations must weigh several alternatives.what most lant engineers will examine is how to solve the moisture roblem, at the source, in the comressor room.this normally involves major caital exenditures in the form of relacement refrigerated or desiccant air dryers.another alternative is to solve the moisture roblem, at the oint-of-use, with membrane air dryers. A Common Scenario Most ul and aer mills use refrigerated dryers which are undersized.they were sized for maximum ambient temeratures of 100 F while, in reality, many aer mills see ambient temeratures of 120 F, on a regular basis.the difference between these temeratures is tremendous in heat load and moisture content.to comensate, a refrigerated dryer needs 30% more caacity to maintain dew oint (which it doesn t have). INLET AIR TEMP REFRIGERATED 100 PSIG CORRECTION FACTOR 100 F F F 0.70 The result can be a significant amount of moisture leaving the air comressor room and traveling downstream, through (sometimes miles) of iron ie which begins to rust. A combination of water moisture, liquid and rust-flakes will arrive at a oint-of-use alication for comressed air. A Simle Solution Membrane dryers offer the convenience of being very small and can be installed in-line, near the alication in question. Comressed air enters the head the membrane dryer and comes into contact with membrane fibers.the fibers are able to searate the water vaor from the oxygen molecules. Differential in ressure moves the water vaor to where a side stream of rocess air (swee air) can remove the water vaor to ambient. It should be noted that some membrane dryers will also swee out the nitrogen with the water vaor making the comressed air un-breathable. The comressed air (now clean, dry, enriched oxygen) now exits the outlet ort for use. Membrane dryers will offer a dew oint range between +50 F and down to -40 F, deending uon the inlet air conditions. If a membrane dryer is hit with higher temeratures, then dew oint will suffer and vice versa.the oint-of-use alication can simly size for worst-case scenarios and thereby ensure an uninterruted suly of clean, dry air. Image Courtesy of SPX Dehydration & Filtration 27

28 COMPRESSED AIR BEST PRACTICES 0 1 / 0 7 Focus Industry MEMBRANE DRYERS AT PAPER & PULP FACILITIES Pre-filters Are Required Membrane dryers cannot remove liquid water and there will be lenty coming downstream.they also cannot filter solids and there will be lenty of rust flakes arriving as well. If liquid water hits the membrane fibers, they will be ruined. No warranty will cover a membrane dryer against a slug of liquid.the costs to dry the fibers are also more than the cost to buy a new dryer. Two re-filters, therefore, are always recommended with a membrane dryer.the first should be a 1 micron articulate filter and the second an oil coalescer.to facilitate timely maintenance, most suliers offer automatic alarms which can notify maintenance when a filter element change-out is necessary. Most are measuring differential ressure across the element and sending a signal from there. Managing Purge The swee air, which is used to carry the water vaor out of the membrane dryer, can and should be managed. Left unchecked, this oen ort is caable of urging 20 30% of the comressed air flowing through it. Different manufacturers offer different solutions to reducing this urge flow. Most solutions involve urchasing otional check valves or other valve configurations designed to manage urge air losses. The comressed air savings are worth the investment. Fast & Easy Sometimes the caital isn t available to relace all the dryers in the comressor room. Often the alication in question cannot wait another six months for clean, dry comressed air. Membrane dryers offer a solution, within one week at very reasonable costs, to a troublesome oint-of-use roblem with moisture in comressed air. For more information, lease contact Comressed Air Best Practices at rod@airbestractices.com 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 *Information required: First Name: Last Name: Checks should be made out to Smith Onandia Communications, LLC. Questions, call Patricia Smith: Comany Name: Street: City: State (Province): Country: Zi Code: Phone: 28

29 Focus Industry COMPRESSED AIR 0 1 / 0 7 BEST PRACTICES Alternative Energy: METHANE BIOGAS BY PAUL GREEN High Pressure Air Comressors Oen Door for Methane Biogas The roduction of methane biogas continues to gain momentum as an alternative energy source and as a way to reduce greenhouse emissions. Dairy and cattle farms in the U.S. are considering the business oortunities that methane resents them.traditionally seen as a fuel source caable of generating on-site electricity, high-ressure comressors are now making methane biogas a roduct which can be roduced, stored, and shied to Comressed Natural Gas (CNG) markets such as vehicles and industry. What is Methane Biogas? Methane Biogas is roduced by the controlled decomosition of livestock waste roducts.the anaerobic digestion rocess involves the breakdown of organic wastes, by bacteria, in the absence of oxygen.the acid-forming bacteria create a Methane Biogas comosed of methane, carbon dioxide, and traces of hydrogen sulfide, ammonia, and water vaor. Methane Biogas has an energy content of 600 BTU/ft 3. Where does Methane Biogas come from? The livestock wastes targeted are dairy cows, beef-feeder cows, and market hogs.the rimary oortunities lie, however, with cattle farms and dairies.the average dairy cow will roduce 30.2 cubic feet of biogas er day.this will translate into 18,000 BTU s of net energy er day. The greatest areas of cattle and dairy farms are found in the Midwest and in California. A leader in environmental rotection and concern, California has articularly good reasons for using bio-methane.the state is home to more than 1.7 million dairy cows, with a technically feasible otential for roducing about 18 billion cubic feet of methane a year equivalent to over 150 million gallons of gasoline. METHANE BIOGAS* COMPOSITION BY VOLUME Methane 60% Carbon Dioxide 35% Hydrogen Sulfide 1.67% Ammonia 1.67% Water Vaor 1.67% VARIOUS FUELS* ENERGY CONTENT Methane Biogas 600 BTU/ft 3 Natural Gas 1,000 BTU/ft 3 Proane 92,000 BTU/gallon Butane 104,000 BTU/gallon Gasoline (regular) 120,000 BTU/gallon Diesel fuel 138,000 BTU/gallon Dairy Farm in Wisconsin Producing High Pressure Methane Biogas 29

30 COMPRESSED AIR BEST PRACTICES 0 1 / 0 7 ALTERNATIVE ENERGY: METHANE BIOGAS Focus Industry High Pressure Comression of Methane Biogas Oens New Markets Methane Biogas has been used directly for cooking, lighting, sace heating, water heating, grain drying, gas-fired refrigeration and air conditioning. It has also been transformed into electricity through the use of internal combustion, enginedriven generators. On-site use has been the first alication due to the challenges resented by storing and moving Methane Biogas. Methane Biogas at ambient ressure is simly too bulky to ut in storage cylinders and transort in a cost-effective manner. Paul Green, High Pressure Comressor Engineer, ComAir Comressing Methane Biogas to higher ressures makes the gas easy to bottle and transort to customers.a comressor comany, ComAir, installed a highressure comressor system, in early 2006, at a dairy farm in Wisconsin.The manure from 1600 head of dairy cows is being converted into Methane Biogas and is then comressed u to 3000 sig for lacement into transortable storage cylinders. The dairy has already found local customers in local industry and local CNG vehicle re-fill deots. A secialist in high ressure air comressors, Mr. Paul Green of ComAir, notes The break-even oint is 1500 head of cattle.we are seeing cooerative efforts of 3 4 farms, of 500 head of cattle, making this work as well. Methane Biogas at High Pressure* PRESSURE (PSI) DENSITY (BTU/FT 3 ) ENERGY CONTENT (BTU/FT 3 ) 14.7 (atmoshere) , , , , ,561 A 5-Ste Production Process There are five stes in the roduction of Methane Biogas.The first ste, of course, begins with the roducer (the cow) who roduces a roduct, Ste 2 (manure). Ste 3 is in a digester, which excludes oxygen and creates an environment where the bacteria can create Methane Biogas. Methane Biogas is then comressed u to 150 sig and urified in a dryer (Ste 4). Finally, the gas is then comressed in a high-ressure air comressor/booster (Ste 5) and stored in cylinders ready for transortation or for filling Natural Gas Vehicles (NGV s). 30

31 Focus Industry 0 1 / 0 7 COMPRESSED AIR BEST PRACTICES The high-ressure comressor designs are recirocating-tye comressors which come in air and water-cooled ackages. Pressure caabilities go as high as 6000 sig and flows can range from 8 1,000 scfm. Package features will tyically include: Ste 1: The Producer Comact modular design for small footrint with maximum flexibility Well balanced comressor design which requires no secial foundations Individual comression stage searation uses high-efficiency searators that reduce moisture carryover between stages, thereby increasing comonent life Gas-recovery system means no loss of gas to the atmoshere Comlete set of safety tris, indicators and PLC controller Packaged as ready-to-run modules Ste 2: The Product For more information contact Mr. Paul Green at ComAir USA: Tel: , aul.green@comair.com or visit *Source: Methane Fuel Gas from Livestock Wastes A Summary, James C. Barker, Professor and Extension Secialist, Biological and Agricultural Engineering, North Carolina State University, Publication Number: EBAE Ste 3: Digester at Dairy Farm Ste 4: Gas Cleaning Ste 5: ComAir Gazack High Pressure Comressor 31

32 COMPRESSED AIR BEST PRACTICES 0 1 / 0 7 Comressed Air Industry COMPANY PROFILE PNEU-LOGIC Comressed Air Best Practices interviewed Mr. Bill McNamara (President) and Mr. Bryan Anderson (Director of North American Sales) of Pneu-Logic Cororation, based in Portland, Oregon. Comressed Air Best Practices: Good morning! How was Pneu-Logic formed as a comany? Good morning. Since 1999, a grou of comressed air industry engineering rofessionals had been working on some innovative technologies designed to significantly reduce energy consumtion and costs for industrial comressed air systems. Pneu-Logic was officially formed, in January of 2005, to commercialize these technologies worldwide.we received initial financial backing from some ublic organizations dedicated to industrial energy efficiency, and additional rivate investments continue develoing Pneu-Logic s technology. Can you describe the mission of Pneu-Logic? Certainly. Our atented and innovative technology rovides the most advanced energy saving management and control systems for industrial comressed air systems available today in the world. Simly stated, the cost of electrical energy required to generate comressed air is a very large and under managed ercentage of most comany s total industrial electrical energy costs (an average of 15%), and a cost that continues to increase every year. Providing comanies with substantial energy cost savings, reducing energy consumtion, and roviding a much more stable and reliable suly of comressed air is what Pneu-Logic can do right now for virtually any industrial comany in the world. To give you a sense of scale for otential savings involved, we just returned from a gold mine in South Africa where we are roosing a Pneu-Logic solution for their installed caacity of 101,000 comressed air horseower.we will be saving them, at a minimum, 10% of their total comressed air energy costs, resulting in a electrical energy cost savings of $1 to $1.2 million er year. 32

33 Comressed Air Industry 0 1 / 0 7 COMPRESSED AIR BEST PRACTICES How do you work with customers? Long-term artnershis are how we do business with both our end user customers and with our Pneu-Logic Authorized Resellers worldwide.we work together in close artnershi with comanies who are committed to saving energy and costs which is what we are all about.we rovide strong technical, engineering and customer suort, and focus on getting the best results ossible for each customer s unique installation. Most existing comressed air systems don t have a holistic or system-wide view of measuring and managing oerating conditions in across all devices at the same oint in time. Existing controllers tend to be discrete in their focus, often monitoring one comressor at a time. In the real world, comressed air systems are comlex with many variables that need to be observed in real time and controlled. Working together as artners with our customers, we look at the entire system and imlement a true demand-based comressed air management solution, sulying only what and when the demand requires. Mining Customer of Pneu-Logic Can you describe your flagshi roduct the Pneu-Logic 3000? Sure.The Pneu-Logic 3000 is a comuter and sensor network-based industrial control and management system for comressed air.the essential rincile of Pneu-Logic s technology is to measure and mange air flow in the system, along with air ressure changes, in order to determine what the true demand of the system really is.the PL3000 is then caable of recisely controlling and managing any combination, of any tye or manufacture, of air comressors that are available throughout the customer s system.this results in the aroriate amount of comressed air being sulied, with very little variation, in the most energy-efficient manner ossible with the existing equiment. Pneu-Logic

34 COMPRESSED AIR BEST PRACTICES 0 1 / 0 7 Comressed Air Industry PNEU-LOGIC A lot of comressor sequencers focus just on air ressure, right? That is correct, and that is where our atented technologies and rocesses come into lay.we measure air ressure AND air flow.we lace air flow meters, which use high-quality elements, in critical oints within the comressed air distribution network.we concentrate on critical source and consumtion areas as oints for measurement of both demand and suly managed system resonse. There are two things to watch out for if a facility is only measuring lant air ressure: 1. The measurement of ressure in a comressed air system does not always seak accurately to the real suly of air flow needed for the work being erformed 2. Pressure based management systems almost always lead to overressurization as a form of safety factor, in order to comensate for insufficient air flow to meet roduction demand which consumes more energy than is necessary. For many years industry has been trained to think and talk in terms of air ressure. While it is not wrong to think about ressure, it simly is whole icture nor is it the most imortant asect of comressed air in relationshi to work.the real measure of the actual work erformed by any comressed air system is the air flow itself, within the required ressure range. For examle, if you have enough static air ressure, this does not at all guarantee you will have enough air flow caacity to erform the required work. Only the flow or air itself erforms the necessary transfer of energy to the consuming device. It is also a fact that increased air ressure also increases leakage rates due to increased stresses at joints and every couling and connection oint.these stress related issues only get worse when there are significant fluctuations caused by inadequate or nonexistent comressed air management systems. How does information from the sensors reach the PL3000? 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: Every customer infrastructure is unique, and so we adat the Pneu-Logic installation to meet their secific needs. For examle, in some factories we connect to an existing Local Area Network (LAN). In others, we use direct data-signal wires. Others larger installations have used uses radio or networks. The PL3000 was designed as a network comuter system from its incetion, and so it can work with virtually any connectivity requirements at any customer facility. US Naval Shiyard Customer of Pneu-Logic *Information required: First Name: Last Name: Comany Name: Street: City: State (Province): Country: Phone: Zi Code: 34

35 Comressed Air Industry 0 1 / 0 7 COMPRESSED AIR BEST PRACTICES You describe industrial rocess latency as a big cost savings oortunity can you elaborate? Actually, the otential for roductivity increases, reduced rocess related soilage, and imroved quality resulting from the use of Pneu-Logic s fair flow based management system can often exceed the total energy savings.aside from reducing over-all lant ressure requirements, we lace a strong focus on eliminating industrial rocess latency in a facility. Process latency is caused whenever a manufacturing rocess is sulied with unstable (substantially fluctuating) air flow and ressure. Unstable working conditions make it very difficult for a machine or oerator, for examle, to increase the outut of the machine. Unstable air flow and ressure will also increases maintenance and wear costs, increase soilage rates, and reduce over-all machine life-cycles. By roviding stable comressed air flow and ressure to critical rocesses, we have seen measured roductivity imrovements of 1.5% occur in some major manufacturing facilities. What kind of metrics and reorts can be generated? Many comressor sequencers or on-board comressor PLC s do not rovide much in the way of analytics or reorts. Pneu-Logic s technology rovides standard and customizable business-metrics and reorts which will ermit the energy costs, related to comressed air, to be managed and reduced. For too many years now, manufacturing facilities have not had the ability to directly measure and manage their comressed air system.this is substantial oortunity available now to most factories. Many of our customers feel that the reorting caabilities of the PL3000 is an essential feature. Eliminating. rocess latency has realized roductivity imrovements of 1.5% with our customers BILL MCNAMARA, PRESIDENT, PNEU-LOGIC CORPORATION How is your comany structured? We work directly with end users in North America and worldwide through our Authorized Reseller network, or directly. We also have a strong inside suort team which hels distributors, and a offer strong technical suort caabilities to our customers. We are currently building an international network of Resellers who share our commitment to energy-savings and long-term artnershis. Thank you Pneu-Logic for your insights. For more information lease contact Mr. Bryan Anderson, Pneu-Logic Cor., tel: , bryan.anderson@neu-logic-cor.com Pneu-Logic Personnel Bryan Anderson (Director of North American Sales) and Dusty Smith (Manager of Professional Services) 35

36 COMPRESSED AIR BEST PRACTICES 0 1 / 0 7 Comressed Air Industry ARROW DRYERS BY McINTIRE BY JIM DONOHUE As most eole in the comressed air and gas industry are aware, Arrow Pneumatics sold their dryer division to McIntire Comany of Bristol, Connecticut in December of Given the current climate in the industry, this was not a surrise. However, the biggest question on most eole s minds has been Who is McIntire? McIntire Comany was founded in Parsiany, New Jersey in They started in business by making refrigeration filter dryers and soon exanded their line to include cartridge filters, small regenerative dryers, humidity indicators and other neumatic drying equiment and accessories. Business boomed throughout the 40s and 50s but it wasn t until the mid 1960s when McIntire detoured from industrial roducts. Refrigerated Dryers CFM 36

37 Comressed Air Industry 0 1 / 0 7 COMPRESSED AIR BEST PRACTICES McIntire s new home was built in 1999 and is dedicated to the manufacture of comressed air dryers. Also located in Parsiany New Jersey was AT&T s research and develoment arm, Bell Labs.This division created many of the household communication items that we now take for granted. However, in 1963,AT&T had a new need for a machine that could ressurize underground telecommunication cables to revent moisture from entering and destroying the cable. Given their stellar reutation, the first call was to McIntire. McIntire soon introduced a new roduct line of comressor/dryer ackages that were used by the Bell Comanies to ressurize both underground and arial cables. Over the following years, McIntire focused on roduct imrovements and innovations and has been the benchmark for other dryer manufacturers who have tried to comete in this marketlace. However, it wasn t until 2001 that the world would come to know the greatness of McIntire roducts. Beginning in the early 1990s, McIntire began an aggressive camaign to grow their business within the telecommunications industry by acquisition. By 1999, McIntire had acquired three comanies,adk Pressure Equiment, a cometitive manufacturer of telecommunication air dryers; Dahl, a manufacturer of secialized fittings, manifolds and accessories for cable ressurization and Western Progress, Inc. a manufacturer of confined sace entry equiment.also, due to the changing needs of their customer base McIntire began working with customers to roduce customized air ressurization roducts and ackages. One such roduct allowed our nation rise from the ruins of a New York City landmark. Prior to the events of 9/11, McIntire built a mobile comressed air system for the hone comany in Manhattan.The intention of this system was to rovide comressed air to telehone central office switching stations in the event of a ower outage or brownout. Manhattan is home to some of the largest such switching stations in the country, but the largest switching station in the world is less than a block from what we would come to know as ground zero. McIntire s original roduct ortfolio 37

38 COMPRESSED AIR BEST PRACTICES 0 1 / 0 7 ARROW DRYERS BY McINTIRE Comressed Air Industry McIntire s state of the art roduction facility. As the dust from the collase settled, hone comany emloyees began trying to save what they could.their first move was to start u the McIntire mobile comressed air system.they had no idea what the challenges would be in coming days, but more imortantly they hardly knew where to start.there was extensive damage done to the most critical arts of the central office, arts of the building were comletely flooded due to a nearby broken water main and the building was nearly condemned.workers stormed through the night, sleeing wherever they could, some working shifts in excess of 24 hours.with debris still smoldering feet away, they worked feverishly to regain communications to lower Manhattan. Less than one week after 9/11,America woke to news of Wall Street being oen for business, and life getting back to normal in lower Manhattan.This was due in no small art to the men and women who worked through the night to restore communications, however, when it came time to slice new hone lines, they found that the cables that had been submerged in contaminated water for almost a week were surrisingly usable, due to the constant air ressure being fed to them by the McIntire mobile comressed air system. 38

39 Comressed Air Industry 0 1 / 0 7 COMPRESSED AIR BEST PRACTICES As the economy struggled in the years after 9/11, so did the telecommunications industry. Most of the major Regional Bell Oerating Comanies had begun lanning to relace their coer based communication networks with fiber otics, which do not require ressurization.as McIntire began to realize the growth otential within the telecommunications industry was dwindling, they began to look to other markets in which to exand.the first look was at wireless communications. In early 2005, McIntire introduced an air dryer system secifically designed for use with wireless communications. In late 2005, McIntire announced the acquisition of the air dryer division of Arrow Pneumatics.This was their first ste in returning to the industrial dryer market and their first year in the business was met with many challenges and great success. In early 2006, McIntire moved roduction of the F-Series, High Performance and Heavy Duty Series from Broadview, Illinois to Connecticut.The heatless, heated and blower urge regenerative dryers followed very soon after. The future of the Arrow Dryers roduct line is a romising one. McIntire s vision for 2007 is one of quality and availability at a cometitive rice. McIntire is also dedicated to romoting this roduct line through advertising, attendance at key trade shows and unaralleled suort of our field sales res.also In 2007, McIntire is making electronic timer drains standard on refrigerated dryers under 100 CFM, and energy efficient, zero-loss drains on dryers over 125 CFM.Additionally, develoment of an energy efficient cycling dryer is currently underway, with lans to release it to the market early in the year. McIntire is lanning to continually imrove their marketing materials and web resence while still continuing to imrove service and delivery to offer an excellent overall value to their customers. McIntire also fully suorts several strategically laced remote warehouses, including one in southern California, the Pacific Northwest,Arizona,Texas, Florida and Ontario, Canada. Heatless, Heated and Blower Purge Regenerative Dryers u to 12,000 CFM For more information on McIntire and the Arrow Dryers roduct line, lease feel free to contact Jim Donohue, Sales and Marketing Manager, toll free at or jdonohue@mcintireco.com. Visit us online at McIntire s vision for 2007 is. one of quality and availability at a cometitive rice. 39

40 COMPRESSED AIR BEST PRACTICES 0 1 / 0 7 Comressed Air Industry ROCKWELL AUTOMATION SOLUTION CUTS ENERGY CONSUMPTION BY COMPRESSED AIR BEST PRACTICES Money wasting. breakdowns are now revented with the exansive energy calculations. The Indian tractor manufacturer sought a drive systems solution along with new monitoring systems and an energy fix that would ay for itself in a short amount of time.through energy reduction, the ugrade aid for itself within 13 months. Background New Holland roots go back to its namesake, the small U.S. town of New Holland, Pennsylvania.The New Holland Machine Comany oened its doors in 1895 as a one-man machine reair sho and went on to carve its niche in the 20th century as an innovator of agricultural equiment that is made and sold around the world and has standardized on Rockwell Automation roducts. New Holland Tractors has one of its wholly owned subsidiaries in India and is a leader in the local market and a major layer on the global stage. When the facility, located in Greater Noida, near New Delhi, oened its doors in 1998, it secified the inclusion of Allen- Bradley control systems.today, the lant roduces 1,000 units a month and serves 10% of the Indian tractor market with annual sales of US$100 million. Challenge Energy waste in the comressor line throughout the Indian lant was having a negative effect on rofit margins. The comany sought to imrove energy waste by introducing control and monitoring systems that would minimize energy losses and reduce mechanical and electrical breakdowns in the comressor unit. In the comressor line, excessive energy waste and ressure variation affected several different deartments in the lant, including the aint sho, assembly line, utility area, engineering and machine sho. Increases and decreases in air ressure required constant management because requirements varied from deartment to deartment. Great quantities of energy were wasted because the motor would run at full seed when the comressor switched between load and no load conditions. To reduce costs and imrove its cometitive osition, New Holland India decided to decrease ower consumtion and imrove energy system monitoring of such things as voltage, current, ower factor, load and harmonics.the challenge was to achieve this with a small investment that delivered a quick ayback. Solution New Holland India sought answers from the local System Integrator M/S Elcon System Pvt, Ltd., which artnered with Rockwell Automation for a solution. Working together, the Elcon/Rockwell Automation team roosed a lan that heled New Holland with the decision making rocess.the team gave the manufacturer a demonstration and a 10-day trial eriod.the comany quickly assessed long term savings and chose Elcon/Rockwell Automation over its cometitors. 40

41 Comressed Air Industry 0 1 / 0 7 COMPRESSED AIR BEST PRACTICES BY 35% AT NEW HOLLAND TRACTOR INDIA The solution included the installation of a ressure transmitter at the inut oint of the ressure line and an Allen- Bradley 125 HP Variable Frequency Drive (VFD) to vary the motor seed automatically.the features allowed the motors to run at low seed when more ressure was required and immediately saved energy and imroved the ower factor to unity. With the AC variable seed drive, New Holland could automatically adjust ressure during various oerating conditions without losing oerational efficiency.a solution that offered maximum savings in energy costs. Monitoring rocess details for critical arameters as the ower factor, harmonics and demand load, was achieved with the installation of ower monitors connected to a network running a secialized ower software RSPower32. One monitor was laced in each of the lant s seven key deartments and included six - PM3000 and 1 - PM2. Energy calculations were now achieved automatically along with easy monitoring of such things as triing, voltage diing and ower failure. Results The Rockwell Automation/Elcon solution heled New Holland India reduce energy consumtion by 35% and the system now oerates automatically with no manual intervention. Without losing efficiency of its oeration, New Holland achieves their savings due to their new ability to automatically vary their ressure amounts.the savings means the comany will have aid for its investment within 13 months, a key objective from the start of the roject. The comany also reorts they are now getting automated regular reorts for each deartment and are able to track various trends and data, which have increased efficiency. Money wasting breakdowns are now revented with the exansive energy calculations. Moreover, the comany is now able to measure and correlate ower consumtion with roduction outut. New Holland India assistant manager and lant engineer Pawan Ual said he is extremely hay with the results. MAXIMIZE ROA THROUGH NON-INTERRUPTED OPERATION Comuterized Maintenance Management System The realization of savings by controlling our comressors has been a remarkable achievement, he said, adding that the suort system was key in the oerational success. New Holland India lans to involve Rockwell Automation in future energy saving undertakings and PLC/SLC based automation rojects. The architecture on the following age deicts Rockwell Automation s concet of an Information Enabled Enterrise. The area outlined with a brown dash line reresents the resent automation level under discussion in this document. The remaining ortion illustrates a host of solutions that Rockwell Automation can rovide today to integrate the lant floor to the enterrise and beyond. For more information lease visit INTEGRATING PLANT FLOOR THROUGH THE ENTERPRISE AND BEYOND e-procurement Remote Diagnostics, Management RA.com Conditions Based Monitoring Legacy Devices Motor MRO Suliers Suly Chain Mgmt Modeling / Data Analysis / OEE Analysis / Scheduling / Tracking / Transacting Drives Power Monitor ERP Suly Chain Partners Plant Machines / Utilities Controller Field Devices Plant Suervisory / Advanced Diagnostics MCC MAXIMIZE ROI THROUGH IMPROVED YIELD & SPEED The Web Transortation e-marketlace Enterrise Systems Sales & Oerations Planning, Material Requirement Planning, Caacity Requirement Planning, Suly Chain Management Manufacturing BusinessWare Inventory Management, Production Scheduling, Material Tracking, Maintenance Management System, Data & OEE Analysis Automation Platforms Milling Machine, Lathe Machine, Shaving Machine, Comressor Controller, Power Monitoring Automation Comonents Smart Maintenance, Modernization Information Enabled Enterrise Comlimentary Otional Linkages Present automation system including existing Motors, MCCs, Field & Legacy Devices, etc. 41

42 COMPRESSED AIR BEST PRACTICES 0 1 / 0 7 Comressed Air Industry INDUSTRYNEWS Press Releases HITACHI INTRODUCES VORTEX BLOWER TECHNOLOGY TO NORTH AMERICA TARRYTOWN, NY, November 13, 2006 Hitachi America, Ltd., Industrial Systems Division, today announced introduction of Vortex Blower Technologies into North America. Hitachi s 37 years of Vortex Blower exerience and nearly 100 years of comressed air exerience are the foundation for these innovative roducts. Features of both the E-series High Caacity and G-series High Pressure Vortex Blower line include but are not limited to: Flexible alication for both air discharge and suction. Sound levels as low 49 db(a) UL Listing Comletely oil-less design Patented three dimension imeller to rovide high discharge ressures Usage with Hitachi inverters for otimum energy efficiency Hitachi s Vortex Blower roducts are art of the Air Technology Grou, which 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 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:// 42

43 Comressed Air Industry 0 1 / 0 7 COMPRESSED AIR BEST PRACTICES NEW CATALOG FEATURES SERIES QR1 PNEUMATIC PUSH-IN FITTINGS With the QR1 series, Rexroth rovides a comrehensive inch and metric (ISO-G) rogram for its neumatic comonents. In addition to the Mini and Standard rograms, the comlete fitting rogram also includes various function fittings. Rexroth catalog SC features 128 ages of technical and ordering information and a features overview section on Series QR1 neumatic ush-in fittings. Series QR1 (Quick Release) fittings are equied with a user-friendly oval lastic release ring that enables fast connection and release of comressed air tubing, making them easier to use than standard ush-in fittings. The Mini design has been created for lastic tubing ODs of 1 8" to 1 4" and 3 6 mm.this variety of fittings is comletely new at Rexroth and rounds out the roduct sectrum secifically for the small handling sector.the Standard design fittings can be used for tubing ODs of 5 32" to 1 2" and 4 16 mm. Products such as check, ball and flow control valves are also included in the range of function fittings. Bosch Rexroth AG, art of the Bosch Grou, achieved sales of aroximately $5.7 billion (4.6 billion Euro) in 2005 with over 28,200 emloyees. Under the brand name of Rexroth the comany offers all drive and control technologies, from mechanics, hydraulics and neumatics to electronics and associated service. Over 500,000 customers worldwide utilize Rexroth s unique technological knowhow to imlement their innovative and future-oriented systems and machine concets.the global layer, reresented in over 80 countries, is an extensive sulier of comonents and systems for industrial and factory automation and mobile alications. For more information visit Please Direct Reader Inquiries To: Eric Deist Account Coordinator Lead Management Services MarketSense 681 Commerce Street Burr Ridge, IL Phone: (630) , ext. 160 Fax: (630) edeist@market-sense.com 43

44 COMPRESSED AIR BEST PRACTICES 0 1 / 0 7 INDUSTRY NEWS Press Releases Comressed Air Industry PARKER HANNIFIN INTRODUCES NEW P5T2 SERIES SHORT-STROKE THRUSTER Wadsworth, Ohio, December 6, 2006 The Actuator Division of Parker Hannifin Cororation (NYSE:PH) introduces the new P5T2 Short-Stroke Thruster. The P5T2 Series features short-stroke, heavy-duty erformance in a smaller footrint than conventional thrusters that use external cylinders. Parker s innovative design of the P5T2 addresses requirements in the ackaging, conveyor and assembly markets where available sace is limited and loads are tyically substantial.the P5T2 Series is ideal for handling frequent stos on conveyor equiment, taming and ressing on ackaging machinery, as well as the unloading/loading and claming rocesses on assembly machinery. The P5T2 Series is available in 12, 16, 20, 25, 32, 40, 50, 63, 80, and 100mm bore sizes with strokes u to 200mm. Maximum oerating ressure is 1MPa (10 bar/ 145 si). Primary features of the series include standard through-hole mounting on all sizes and available rear mounting when secial ordered on all sizes, ensuring dro-in caabilities for a variety of installations.to orting is standard, but rear and side orting are available on all sizes as well.a true rod-lock mechanism, which stos the unit in current osition uon loss of air ressure, is available on 32mm through 100mm bore sizes. Construction of the P5T2 thruster features an aluminum body and end cas; steel tool late, suort rods, and rod bolts; and a stainless steel iston rod. Standard nitrile seals oerate at temeratures between -18 to 74 C, 0 to 165 F. Fluorocarbon seals are available for high-temerature alications and have an oerating range of -18 to 121 C, 0 to 250 F. A PTFE imregnated comosite bushing is standard on all P5T2 models and rovides high load carrying caabilities with excellent resistance to shock loading. Otional linear ball bearings rovide recision oeration with very low friction and wear. For more information about the new Parker P5T2 Series, contact Parker Hannifin Cororation, Actuator Division. Phone and ask for Catalog AU /US or visit us online at 44

45 Comressed Air Industry 0 1 / 0 7 COMPRESSED AIR BEST PRACTICES AGGREKO OPENS NEW FACILITY IN MIAMI MIAMI (BUSINESS WIRE) Dec. 5, 2006 Aggreko, LLC ( Aggreko ), the world leader in rental ower and temerature control solutions, announced today that, through the acquisition of GE Energy Rentals (Aggreko has just acquired substantially all the GE-ER activities, other than those relating to large gas turbines), it has oened a new facility to rovide rental ower generation, temerature control and oil-free comressed air solutions to industrial and commercial oerations in South Florida. For the ast several years, we have been serving the Miami market through our facilities in North Florida, said Tim Ainslie,Area Sales Manager. With Aggreko s global acquisition of GE Energy Rentals, we have acquired their Miami location and will now have the ability to serve this market directly with an exanded fleet, including generators, oil-free air comressors, chillers, air conditioners and ancillary equiment. In addition, our strong sales and service team will be suorted by our nationwide network of over 50 locations and our staff of exerienced rofessionals. For over 20 years,aggreko has been roviding rental ower and temerature control solutions throughout North America to the entertainment industry, including sort events such as the PGA Tour, the Olymic Games and Suer Bowls; and to industries such as shiing and associated ort services, construction, facilities management and manufacturing. Aggreko s new Miami facility, located at 2100 NW 82nd Ave, is ideally situated to serve industry and commercial interests throughout South Florida. It is aroximately five miles from the Miami International Airort and adjacent to the Port of Miami. CONTACT: Aggreko, LLC Rod Jay, Marketing Manager Amy Stine, Communications Secialist Amy.stine@aggreko.com 45

46 COMPRESSED AIR BEST PRACTICES 0 1 / 0 7 INDUSTRY NEWS Press Releases Comressed Air Industry REDUCED NOISE LEVELS! One-to-one direct drive for maximum efficiency and reliability Kaeser Comressors Inc. announces the latest additions to our direct drive rotary screw comressor line the new FSD series comressors in h models. Available in flows from cfm and ressures to 217 sig, FSD comressors are designed for efficiency, reliability, and minimal maintenance. These state-of-the-art units feature our otimized Sigma Profile airend, atentending Sigma Control system and the latest one-to-one direct drive technology. The FSD units are true direct drive comressors with an oversized airend connected directly to the motor via a maintenance free couling for maximum efficiency. Units are now available in either air-cooled or water-cooled models. Kaeser s unique cooling air flow design includes a owerful radial fan that significantly reduces noise levels and rovides suerior cooling.all models are fitted with a re-designed, high-efficiency searator system for extremely low oil-carry over. And for alications with varying demand, the FSD is also available with variable seed drive. For more information, lease call or visit us at 46

47 Comressed Air Industry 0 1 / 0 7 COMPRESSED AIR BEST PRACTICES NEW AIR SERVICES FROM FESTO Air Consumtion Analysis Using too much or not enough comressed air? Let Festo hel you find the answer... With the growing demands of end users to validate their air consumtion figures, there is a major incentive to imrove erformance. What may hamer many is the lack of skills and aroriate technologies for accurate air consumtion measurements. The new Air Consumtion Analysis Service from Festo gives machinery OEMs the ability to document air usage figures for new or existing equiment.the detailed analysis rovided by Festo enables manufacturers to reduce comressed air costs and otimize distribution networks. From flow measurement on the machine level to the analysis and documentation of the values calculated, tailormade solutions hel the machine builder to calculate and document the vital characteristic values for the end user resulting in a more reliable and efficient comressed air suly system. Air Consumtion Analysis includes: Measurement of comressed air consumtion and ressure Generation and documentation of defined values With the Air Consumtion Analysis, you can exect: Highest Precision through the use of the most modern, regularly calibrated and tested measuring equiment and software Raid Availability through a comrehensive and worldwide service network High Levels of Cometence through continuously trained neumatic secialists Reduced Costs the urchase of exensive measuring and testing equiment is no longer necessary Customer-Secific Solutions each service is tailored to the individual machine and includes secific suggestions for imrovement. For more details, lease visit: <htt:// 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. Comlete suort through your Festo technical consultant 47

48 COMPRESSED AIR BEST PRACTICES 0 1 / 0 7 INDUSTRY NEWS Press Releases Comressed Air Industry NEW EASIDEW 2-WIRE DEWPOINT TRANSMITTER Kahn Instruments,Wethersfield, CT, a leading manufacturer of advanced moisture-measurement instrumentation is roud to announce that we have ugraded our Easidew Dewoint Transmitter.The new and imroved Easidew 2-Wire Transmitter is a low cost, rugged dewoint transmitter for continuous measurement in comressed air or rocess gas. New and imroved features include: The ability to be connected in a 2-wire, loo owered configuration, while maintaining comlete backward comatibility with all existing 3-wire installations An outut that is configurable in PPMv moisture content (0-100, and PPMv ranges) A new 10 micron HDPE sensor guard designed to show contamination for service ease The Easidew Transmitter is economical to urchase, install and maintain.volume manufacturing allows Kahn to kee the rice low. Installation costs are minimal, because of the transmitter s ruggedness and simlicity. And ongoing oerating costs are low, because the Easidew Transmitter is reliable and durable. Only eriodic re-certification is required to maintain calibration accuracy. Kahn even offers an exchange rogram so a customer s rocess is never out of oeration. For further information, contact: Kahn Instruments, Inc. 885 Wells Road Wethersfield, CT Phone: (860) Fax: (860) hygros@kahn.com Web: Contact: Robert T. Bailey, Product Manager Imroved software and firmware to rotect calibration from the most severe levels of EMI The Easidew Transmitter has a dewoint measurement range of -148 F to +68 F and an accuracy of ±3.6 F. The instrument also features a field adjustable 4-20 ma linear analog outut, resettable failure modes for Over Range, Under Range and Sensor Fault conditions, and temerature comensation. 48

49 Comressed Air Industry 0 1 / 0 7 COMPRESSED AIR BEST PRACTICES FLUID METRICS INTRODUCES COMPRESSOR OIL PURIFIERS Increase Fluid Life and Air Comressor Reliability with Acid Adsortion and Ultra-fine Filtration Atlanta, GA Fluid Metrics, LLC introduces a revolutionary, roactive maintenance device designed secifically for oil-flooded rotary screw air comressors. The Fluid Metrics Comressor Oil Purifier (COP), with ProACT Acid Control Technology, combines rorietary ion exchange acid adsortion with ultra fine article filtration to remove the acids and catalytic solids known to accelerate oil degradation, wear, corrosion and fouling in rotary screw comressors. The system emloys a atent-ending, K9 housing cartridge manufactured by Schroeder Industries. Fluid Metrics recognized that secific fluid contaminants (acids and ultra-fine solids) were the root cause of most comressor reairs and failures and, with the elimination of these ollutants, comressor users would realize dramatic extensions in the service life of exensive comressor fluids, searators, bearings, and shaft seals. With this knowledge, Fluid Metrics turned to the recognized leaders in filtration and fluid conditioning, Schroeder Industries, and leading innovators in synthetic comressor lubricants and liquid searation, The Dow Chemical Comany, for state-of-the-art technologies designed to target and remove these contaminants. The result of this collaboration is an innovative, cost-effective line of COP s that easily mount onto any rotary screw comressor to urify the oil, reduce maintenance and oeration costs, and increase comressor reliability. Unlike traditional and more costly reventative maintenance techniques that rely uon the regular relacement of exensive fluids and searators to rid comressors from contamination, the COP is a roactive maintenance device that selectively removes destructive, clearance-sized solids and corrosive acids before they can negatively imact fluid and comonent service life. The heart of the COP s ProACT Acid Control Technology is its atentending cartridge design by Schroeder Industries. The COP cartridges utilize a dual core design that incororates an outer core of high dirt holding caacity synthetic media to remove solids down to 3 microns absolute, followed by an inner core of rorietary ion exchange media secially develoed by Dow Chemical to adsorb and neutralize acids that are roduced and accumulated in synthetic comressor fluids. comressor energy consumtion by as much as 3 ercent. Performance of the COP is easily verified through routine oil analysis by monitoring fluid Total Acid Number (TAN), H and ISO article counts. The COP installs easily in an auxiliary loo to the comressor s main oil circuit. Unlike standard full flow oil filters, where filtration erformance is limited by ressure dro, the COP urifies a relatively small sli-stream of oil at low velocities and high surface areas, thereby maximizing contact time with both filtration and acid removal medias. Each COP comes comlete with its own installation kit which includes a mounting bracket, high ressure suly and return hydraulic hoses, flow meter, sight flow indicator, automatic vent, samle and drain valves, and isolation valves that ermit cartridge relacement without having to shut down the comressor. The Fluid Metrics COP can be used on any brand rotary screw air comressor and with all of today s most common comressor fluids, including Polyglycol/POE, PAO, Food Grade PAO s, Hydro-treated Petroleum, and Ester based fluids. The COP will benefit all comressors, whether they are oerating in a normal environment and achieving full fluid life, or oerating in a severe environment with drastically reduced fluid life. The COP is ideal for any industrial end-user of oil-lubricated rotary screw air comressors, including the ul and aer, mining and steel, chemical rocessing, food and beverage, oil and gas, caret and textile, and general manufacturing markets. About Fluid Metrics, LLC Fluid Metrics, LLC is the leading rovider of roactive maintenance acid control technologies to the comressor industry. Fluid Metrics is dedicated to creating value for its customers by designing and marketing engineered solutions that reduce user cost and imrove equiment erformance and reliability. For further information about Fluid Metrics and its roducts, call or visit About Schroeder Industries Schroeder Industries designs, manufactures and markets filtration roducts for the fluid ower industry. Schroeder is a leader in filtration and fluid conditioning. Their exertise in filtration technology, suerior filter and element manufacturing caabilities, dedication to customer service, and roduct suort are the reasons Schroeder is considered The Filter Comany. For further information about Schroeder Industries and its roducts, call or visit This unique combination of searation technologies has roduced dramatic results, extending comressor fluid life by three to five times, extending searator life by two to three times, and lowering 49

50 COMPRESSED AIR BEST PRACTICES 0 1 / 0 7 Comressed Focus Air Industry Job Oenings in the Comressed Air Industry GRS GRS FLUID HANDLING REGIONAL SALES MANAGER CALIFORNIA GRS Fluid Handling is working on a search for a client of ours a strong comressor manufacturer, serving a variety of industries worldwide. They are a strong comany with a track record of customer satisfaction. This osition, as a Regional Sales Manager, will sell Industrial Air Comressors throughout a California territory. Requirements: 2-5 years sales exerience; ***Must have channel management exerience Knowledge of California account base as well as surrounding areas Some alications exerience, referably dealing with comressed air systems A strong ersonality and attitude A college degree is strongly referred for this osition. This is a highly visible osition that offers a chance for advancement, great benefits, challenge and oortunities with a strong, stable comany. SALES POSITION NORTHERN FLORIDA GRS Fluid Handling is working on a search for a leader in the comressor industry. Their resence in Florida makes them one of the strongest comanies in comressed air, with strong roduct offerings and great service. This osition, in sales, will be resonsible for targeting otential OEM customers and introducing roduct to new markets. Requirements: Knowledge of comressed air roducts and systems 3-7 years Outside Sales exerience Strong sales resence, and the ability to make large scale sales Ambition to succeed and desire to bring solutions to industrial businesses Residence or relocation in Northern Florida Along with being in a beautiful location, this osition offers daily challenges and strong comany suort. It interacts with sales, marketing, and engineering, and offers the chance to rogress in a comany that rewards excellence. For more information on these ositions, any other ositions we are working on, or to learn more about GRS and GRS Fluid Handling s recruiting services lease send an to us at cabc@grsrecruiting.com. 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 $ $ Beta Drive Mayfield Village, OH (440) cabc@grsrecruiting.com atricia@airbestractices.com, tel:

51 Give your business a solid shot of ideas, machinery and equiment, technologies and trends, and global networking oortunities. Learn about new alications and rocess imrovement at WESTEC s new Plant Tours & Sessions. It s all at WESTEC 2007, the rimary resource for West Coast manufacturers. Discover strategies for streamlining your oerations, imroving roduct quality, and cometing vigorously in world markets. Transact serious business on the show floor. Network with industry leaders at the SME International Awards Gala. Don t miss WESTEC One solid event. March 26-29, 2007 Los Angeles Convention Center Los Angeles, California The Total Manufacturing Exerience For more information visit Or call

52 Consulting Services Comressor Products Clean Air Treatment Products Control Products Kaeser SFC comressors: The roduct of a better idea. In the drive to save energy costs by recisely matching air roduction to air demand, Kaeser s Sigma Frequency Control comressors are the most energy-efficient variable seed, single-stage comressors you can find. The cometition simly can t comare in erformance or quality. Kaeser SFC comressors offer a wider range of oeration, from 20% artial load to 100% full load. Plus, our oversized Sigma Profile TM airend rotates at lower seeds for greater outut while consuming less energy. With near-unity ower factory, built-in hase rotection, and suerior ressure control, our SFCs are built for a lifetime! And, since we offer them in the widest range of sizes most with integral dryer otions we have just the right model for your needs. Of course, the best way to areciate the suerior engineering of Kaeser SFC comressors is to see them in oeration, so call to find one near you. COMPRESSORS info.usa@kaeser.com Kaeser Comressors, Inc., P.O. Box 946, Fredericksburg, VA USA Tel: (800) Fax: (540) Sigma Profile and Built for a lifetime are trademarks of Kaeser Comressors, Inc Kaeser Comressors, Inc.