2/19
Hitting the sweet spot
delivering reliability to Pennant Hills Golf Club
The total package
Opening the door
Compressed air leaks 101
Securing energy efficiency
Saving energy costs with complete blower packages
Meeting Hume Doors' increased demand for compressed air
Getting to grips with compressed air leaks
Efficiently meeting Prowler Proof's fluctuating air demand
Contents
Issue 2/19
3 Introduction
4-7
4 8
Hitting the sweet spot Delivering reliability to Pennant Hills Golf Club
10
Opening the door Meeting Hume Doors' increased demand for compressed air
The total package Saving energy costs with complete blower packages
13 i.Comp Tower Premium quality compressed air for trades and workshop applications
10-12 10-12
14
Compressed air leaks 101 Getting to grips with compressed air leaks
16
Securing an energy efficient compressed air supply Efficiently meeting fluctuating compressed air demand at Prowler Proof
19
KAESER 100 Celebrating 100 years of KAESER KOMPRESSOREN
16-18
Publisher:
KAESER COMPRESSORS Australia Pty. Ltd. 45 Zenith Road, Dandenong, VIC 3175 Tel. +61 3 9791 5999 , Fax. +61 3 9791 5733 E-Mail. info.australia@kaeser.com, https://au.kaeser.com
The publisher accepts no liability for manuscripts and photos submitted without request. Reproduction, including of excerpts, only permitted with written permission. E&OE. Information correct at time of print.
2 | KAESER report
Introduction
We have just celebrated our 100 year anniversary. On 27 June 1919, KAESER KOMPRESSOREN was established in Germany. From a small workshop with a team of 10, Carl Kaeser Senior started producing spare parts and engines for cars, along with gear wheels and special machines for the glass industry. 100 years later and KAESER is now a successful and global compressed air system specialist. KAESER remains family owned and operated presently in the hands of the third generation. Managed by Thomas Kaeser and his wife Tina-Maria VlantoussiKaeser, the company has more than 50 own subsidiaries and is Eckberg, represented by exclusive contract partners in over 100 countries. Peter Managing Director Today KAESER employs in excess of 6,000 staff worldwide and many employees have worked for KAESER for 30 plus years. In fact within KAESER Compressors Australia and New Zealand we and will ensure that we are well positioned to effectively and have many employees who have been with us now for over 20 efficiently serve the Australian, New Zealand and pacific region years, and I myself have been with KAESER for over 35 years. well into the future. KAESER Compressors Australia was actually the second own subsidiary to be established as part of the company's international expansion. Since 1990 we have been providing compressed air sales and service support to customers throughout Australia, New Zealand and the pacific region from our head office in Dandenong, Victoria. This includes supporting many of our international key customers located in the region, as well as delivering bespoke and turn-key compressed air system solutions through our inhouse engineering team.
We trust you will join us in celebrating 100 years of tradition and innovation! In this edition of the KAESER report you will find an update on our 100 year celebrations as well as recent and local case studies which demonstrate how we continue to support our customers in efficiently meeting their compressed air requirements. You will also find some technical articles and product updates. We hope you enjoy this edition!
Over the past 29 years we have also established branch offices in all major Australian capitals as well as branches in Mackay and Tasmania, alongside an extensive network of authorised partners. And, in 2015 we saw a further development in our region with the founding of KAESER Compressors NZ Limited to more closely serve the New Zealand market. Continual reinvestment into the future of the company is very important to KAESER, and we are excited to see ground break on the construction of an extension to our existing Australian head office later this year. This will extend out the original building to twice its size, allowing for additional office and warehouse space,
KAESER report | 3
Hitting the
sweet spot
4 | KAESER report
10 years on: Delivering reliability to Pennant Hills Golf Club
Ten years on and four KAESER Compact series rotary lobe blower packages continue to deliver a reliable supply of low pressure process air to the water recycling plant at Pennant Hills Golf Club, built in 2008 to supply the club with its own secure, sustainable and drought-proof supply of irrigation water.
KAESER report | 5
Nestled in the Hills Shire in the northwest region of Sydney you will find 37 hectares of picturesque landscape which is home to Pennant Hills Golf Club (PHGC). The fourth oldest golf club in Sydney still to be occupying its original site, PHGC was formed in 1923. It holds both Championship and Group One status and has produced some outstanding players who have achieved national and international success not least Tony Gresham, one of the finest Australia amateur golfers to have played the game and Peter Fowler, a successful contender on the professional circuit. With almost 100 years of history, PHGC attest its ongoing durability to a number of factors including the direct ownership of the land as well as the careful maintenance of the course. And as you can imagine, such a beautifully presented eighteen hole course does require some significant commitment to maintenance. Since the club first opened its doors in 1923, it has relied on potable water to irrigate the tees, greens and fairways. However, the millennium drought (which lasted over 10 years from 1997 to 2009) placed extreme pressures on urban water supplies. It saw Sydney’s water storage plummet to its lowest level since 1950 at around 33 percent of capacity. For PHGC this meant restrictions started to come into place on their use of 6 | KAESER report
potable water, ultimately capping their consumption to 10ML/month. Unfortunately that was not enough in the dry summer months to meet their requirements. With the real possibility looming that PHGC could lose their supply of potable water all together, the golf club began investigating how they could reduce or eliminate their reliance on potable water. Ground breaking sewer mining project After investigating a number of options PHGC concluded that developing their own water recycling plant would be the best option and chose Permeate Partners to assist them in the process. Permeate Partners is a specialist consultancy which assist its clients with the investigation, procurement, operation and maintenance of water and waste water infrastructure. A key focus area for Permeate Partners is finding local water solutions - local source, local treatment and local reuse.
unprecedented in Sydney at that time. As the term implies, sewer mining is literally the mining of a sewer system to extract water for further treatment. Sewage is extracted when required and then treated to the quality level required of the application. For PHGC the system provides a reliable supply of high quality recycled water. Designing this ground breaking water recycling plant required consultation and approval from many levels including; Sydney Water, NSW Department of Water and Energy and Hornsby Council to name only a few. Once approvals had been sought work on building the plant commenced. Fortunately for PHGC they had a largely unused piece of land not far from the 10th hole which was less than 100 metres from the sewer. This presented the ideal place to construct the plant.
Through a thorough investigative process, it was determined that utilising the water from a 300 mm sewer which runs adjacent to the golf course using a technique called sewer mining would be the most cost effective option for PHGC.
Low pressure process air Blowers are a key component of any waste water treatment plant, and the water recycling plant at PHGC is no exception. In designing the plant, two 15 kW and two 7.5 kW BB compact series blowers from KAESER were selected to meet the treatment processes requirement for low pressure process air.
Proven in similar applications, sewer mining for such purposes was however
At the heart of the treatment process is a membrane bioreactor. Here the treated
water from the biological reactor is drawn through the surface of a membrane while solids and pathogens are rejected. When the ‘bugs’ - or mixed liquor suspended solids - are rejected from the membrane surface, they are returned to the start of the biological reactor. The water which passes through the membrane can then be reused following further disinfection via UV and chlorine. A reliable supply of low pressure process air is essential to this process. Two of the BB series rotary lobe blower packages from KAESER are installed duty / standby and used for aeration of the biological reactor. Here oxygen is introduced by the aeration blower which increases the bacterial activity. This in turn brakes down the organic matter. The other two BB series rotary lobe blower packages are installed duty / standby and used for membrane aeration. In essence this stops the solids sticking to the outside of the membrane. The all-in-one Compact series of rotary lobe blower systems from KAESER are compact and delivered ready for immediate use with; sound enclosure, integrated electrical equipment, an integrated control system and stardelta starter. Together such features significantly reduced the amount of work required for planning, installation, certification, documentation and commissioning.
As with all KAESER products, the Compact series of rotary lobe blowers are designed and constructed for maximum efficiency, reliability and durability in mind. Together with their minimal maintenance and service requirement, these versatile blowers ensure lowest possible life cycle costs. Ten years on and still going strong The Pennant Hills Water Reclamation Plant commenced operation just over 10 years ago in May 2008 and is capable of producing 650KL of high quality recycled water per day with 2.5ML storage.
Since completion of the plant, Permeate Partners has continued to provide service support. With regard to the blowers, Kurt Dahl, Managing Director at Permeate Partners said: ‘In operation now for over 10 years, they have proven to be reliable and run perfectly. As the plant is nestled within the course, it was important that we selected equipment with low noise levels, and the KAESER blowers have certainly proven to be quiet in operation contributing to the overall minimal noise levels of the plant.’
Approximately 98 percent of the water extracted from the sewer is converted to recycled water while the remaining 2 percent is returned to the sewer as waste
'In operation now for over 10 years, the KAESER blowers have proven to be reliable and run perfectly' activated sludge. At around 30 percent of the size of a conventional bioreactor, for PHGC the membrane bioreactor method has allowed them to minimise their biological process footprint as well as achieving a high level of pathogen removal at 99.9 percent.
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Saving energy costs with complete blower packages
The
total package
Aeration is a central part of the treatment process at a wastewater plant. It is also a major contributor to energy costs. As a result operators are always looking for ways to revamp, replace or modify the blowers and their packaging in order to improve the aeration stage. Understanding what makes an efficient and costsaving blower system is therefore paramount. Here we explain the cost and energy efficiency gains that can be made with complete blower packages. Blower packages assembled by sourcing components from a variety of suppliers is still quite common and usually a result of adding to the blower as new requirements arise. As an example, a blower is determined to be too loud, so a new silencer is sourced. Perhaps even a sound enclosure is purchased. However, this now means that being inside a box, the blower runs warm, so 8 | KAESER report
now the operating temperature must be monitored. Then perhaps it is determined that the blower needs to make more or less air, so a frequency controlled drive is installed. The needs grow and so does the package and its components. There are many versions of these packages in the field and while they may get the job done, there is no clear way to see how efficient they are.
With energy for aeration one of the highest operating costs to a WWTP (wastewater treatment plant) it is therefore essential to understand equipment efficiency in order to better control and manage these expenses. The total package Opting for a fully packaged blower solution is one way operator’s can meet
all of their requirements in the most cost effective and energy efficient manner. Fully packaged blowers have been available for some years now however different manufacturers have different levels of packaging. Most includes the basics; full cabinet enclosure, motor, drive, inlet/outlet silencers, and basic instrumentation. Some manufacturers go a step further and have onboard sensors and controls. Packaged blowers from KAESER for example include a full sensor kit that monitors several points on the machine for pressure and temperature. This information is fed back into the onboard controller which not only monitors these points,
of specific performance (kW/m3/min) can be achieved with complete packaged blowers. Specific performance is the ratio for how much power it takes to generate the desired air flow. When a decision is made on which blower to purchase an evaluation is done to compare all of the quoted blowers. Quite often the values are stripped down to the bare blower block performance before equal values are assigned to each blower for package losses in the form of motor efficiencies, silencer losses and so on. This is done in order to ascertain how much each machine will cost to operate over a period of time. The problem however is that while the blower performance is guaranteed, the package performance is not. Again this is because the end product is assembled from a variety of suppliers, where each of the suppliers it not able to guarantee an end result. H o w e v e r, when the enduser opts for a complete packaged blower system manufactured by one supplier, p r o v i d e d performance values can be guaranteed.
These machines are also fitted with motor starters or a frequency controlled drive. Here again, all of the devices feed into the controller, providing a central point for monitoring and operator interface. A communication module can even be purchased which extracts all of this data to a plant program logic controller (PLC).
Optimised maintenance Whether it is a blower made up of various supplier components or a complete packaged system, the maintenance requirements are the same, i.e. oil, belts, grease and air filters. The key benefit of complete packaged systems such as those from KAESER, are the onboard controllers which keep track of the running hours and maintenance intervals. When it is time to change the oil, inspect the belts or filter, or grease the motor, the controller lets you know. And, in order to clear an alarm the user or maintenance person must log into the controller. All of this activity is kept as a log inside the controller, therefore should a problem occur, all data and activities can be accessed for future reference and troubleshooting.
Saving energy costs with complete blower packages Significant energy cost savings in terms
Rotary lobe versus rotary screw blower packages A rotary lobe blower package such as the
but also makes calculations for differential pressure and temperature. The machine is then able to provide alarms or warnings, notifying the user of impending problems. It can even turn the machine off to prevent catastrophic failures.
ones manufactured by KAESER, have all of the components required of a blower system; silencers, motor, air filter, belts, relief valves, sound enclosure, check valve, sensor kit, controller and starter (contactors or frequency controlled drive). As all plants require all of these elements, every plant can benefit from this design. For most WWTP’s these blowers will be running all day every day. Performance, reliability and longevity are critical to the plant’s operation and compliance. A factory-engineered and developed machine has been optimised through years of experience to provide the best performance and highest reliability. Furthermore, integrating the blower package into a plant’s master control system allows for better product maintenance monitoring which can reduce downtime and repair costs. The rotary screw blower package has the same scope of supply as the lobe blower package. All of the package design concepts and goals remain more or less the same – low noise, easy access to maintenance, and a small footprint – but a screw blower gives a decided boost in efficiency over any lobe-type blower design. Screw blowers offer the advantage of internal compression which can result in up to a 35 percent gain over lobe technology under certain conditions. Screw blower designs are beneficial for all aeration processes, however they are best suited for a process with a constant fluid depth and with extended running hours. Constant fluid depths allow the user to accurately predict the efficiency gains and to realise the expected payback on the investment. Variable fluid depth applications will see fluctuations in efficiency gains and intermittent duty systems will experience extended payback on the investment, both of which will extend payback periods. In these cases, it may be best to stick with the PD lobe machine. If the effort required to install, wire, program and commission a blower is considered, the costs would easily surpass the cost of a complete packaged system. Additionally, the end product would not provide the same level of functionality or protection as the complete packaged system offers. A completed packaged system also gives the peace of mind that the end-user is getting the performance calculated during their evaluation process.
KAESER report | 9
Opening the doo
to compressed a
10 | KAESER report
or
air efficiency
Manufacturing facility expansion: Meeting Hume Doors' increased demand for compressed air
Hume Doors & Timber - one of Australia’s leading door manufacturers - recently invested in an energy efficient KAESER CSD 125 rotary screw compressor to meet the increased demand for compressed air created by the expansion of its Sydney manufacturing facility. Hume Doors and Timber (Hume) is one of the nation’s largest door manufacturers with operations in every capital city and strategically placed regional branches within Australia and New Zealand. Established over 60 years ago and now with over 1,000 employees, Hume proudly remains a 100% Australian owned company. Hume provides innovation in doorway technology and manufactures an extensive range of products - over 2,000 to be exact - for the building industry including the; commercial and industrial, multi-unit, aged care, residential and renovation sectors. From their manufacturing facilities Hume is able to deliver specialist low volume to mass high volume production. In fact, they were the first company to introduce cold pressing technology to allow for the mass production of doors using sustainable practices - a procedure that also greatly reduces power consumption. Hume is committed to operating its entire business process in an environmentally sustainable manner. As such its manufacturing and distribution processes have been designed to minimise their environmental footprint. Innovation, sustainability and recycling
therefore all have a key role in their manufacturing facilities. One way they try and minimise their environmental footprint is by utilising energy to its maximum efficiency. It’s no surprise then, that when it comes to the compressed air systems at all of their manufacturing operations, Hume has long since opted for compressed air equipment that is not only reliable but also highly energy efficient. Compressed air is an important utility to Hume and can be found in use across the manufacturing process, responsible for powering the woodworking machinery such as the sanders and staple guns. Hume recently expanded its manufacturing operation in Sydney. With the expansion came an increased demand for compressed air which the current system could not meet. Eddie Luke, the General Manager at Hume therefore contacted long standing compressed air supplier KAESER Compressors for a solution. KAESER recommended and subsequently installed a CSD 125 rotary screw compressor to meet Hume’s increased demand for compressed air in the most energy efficient manner.
KAESER report | 11
'We have opted for KAESER compressors for many years in our manufacturing facilities' The CSD series rotary screw compressor from KAESER push the boundaries when it comes to compressed air efficiency. These versatile compressors provide significant energy savings in four key ways: At the heart of every CSD system lies a premium quality rotary screw compressor block featuring KAESER’s energy saving SIGMA PROFILE rotors. Operating at low speed, KAESER’s rotary screw compressor blocks are equipped with flow optimised rotors for superior efficiency. The newly-refined rotors found in the latest generation models, together with additional optimisation measures such as reduced pressure losses, are now
12 | KAESER report
delivering between three and six percent better specific power performance compared to previous models.
IE4 motors comply with and exceed prevailing Australian GEMS regulations for 3 phase electric motors.
KAESER’s 1:1 drive design additionally delivers superior efficiency by eliminating the transmission losses associated with gear or v-belt driven systems.
Finally, the SIGMA CONTROL 2 industrial PC-based internal controller ensures efficient control and system monitoring. This dynamically adjusts flow rate to match actual compressed air demand thereby assuring further energy savings.
1:1 direct drive rotary screw compressors provide outstanding performance and enable significant savings. Featuring an IE4 super premium efficiency drive motor further maximises energy efficiency. IE4 motors are the technology of tomorrow, as current regulations introduced in January 2015 simply require the use of IE3 class motors.
Eddie Luke said: ‘We have opted for KAESER compressors for many years in our manufacturing facilities. In fact we have one KAESER that has been reliably in operation now for over 15 years! We have also realised energy savings over the years by opting for KAESER compressors.’
Premium quality compressed air for trades and workshop applications
i.Comp Tower Anyone looking for a super-quiet, efficient and cost-effective supply of quality compressed air for their workshop requires a user-oriented solution. With the space-saving i.Comp 8 and 9, KAESER is proud to introduce a completely new compressed air supply concept that has been specifically developed with this field of use in mind. These units are tough, powerful, compact, easy to maintain, efficient and much more. At the heart of the new i.Comp family is a new drive concept, which provides a multitude of advantages. It delivers the necessary power to cover the required compressed air demand with infinitely variable control. Needless to say, the reciprocating compressor itself is made in Germany and is manufactured to the highest industrial standards for which KAESER is world renowned. Moreover, i.Comp family reciprocating compressors are able to operate with 100 perc ent d u t y cycles. Intelligent solutions such as drawing the air for compression in through the piston head - ensure exceptional filling performance and, as a result, outstanding efficiency.
sound enclosure not only hides an advanced all-in-one compressed air station comprising a compressor and a refrigeration dryer, but also keeps sound levels to a minimum and helps retain system value. KAESER’s field-proven SIGMA CONTROL 2 controller allows pressure preselection and infinitely variable speed operation, as well as connection to a master controller such as the SIGMA AIR MANAGER 4.0. S i n c e i.Comp Tower
systems deliver oil-free compressed air, no oil enters the compressed air supply itself. This in turn eliminates the potential for accumulation of oil-contaminated condensate that would otherwise have to be carefully disposed of. In addition, there is no need for oil changes or oil inspection, which of course further reduces overall service costs. i.Comp Tower systems are the perfect choice for workshop and trades environments, such as in collision repair shops, where a dependable supply of quality compressed air is required.
With a volumetric flow rate of 412 to 580 l / min, the i.Comp Towers can be used for a wide range of workshop and trades applications and assure a constant pressure of up to 11 bar with absolute operational reliability. Made from roto-moulded polyethylene to enable optimum corrosion- and impactresistance, the attractive
KAESER report | 13
blog This article has been taken from the KAESER Australia Blog kaeserknowhow.com.au
Getting to grips with
compressed air
leaks
Unfortunately all compressed air systems will have compressed air leaks however did you realise that statistics suggest the average leakage rate is 25%, with some plants losing as much as 80% of their compressed air through leaks!* That’s a lot of wasted compressed air, a lot of wasted energy and a lot of wasted money. Here we discuss the costs and the culprits, leak detection methods, best practice and ongoing management. The costs So what are the costs to your business of compressed air leaks? Firstly and most obviously, compressed air leaks waste electricity. They are simply demands for air that create no value and they consume flow needed by other productive uses. The result is often decreases in pressure at the points of use. To compensate many compressed air users will just turn up the pressure on the compressor. This actually just makes the situation worse as a leak will waste more air at a higher pressure. You can calculate the annual energy costs for a leak using the following formula: Annual cost of a leak = leakage rate (m3/min) x kW/m3/min x operating hours x $/kWh Take for example just one single 2 mm diameter leak in a compressed air system which runs 24/7 and has a power cost of 15 cents/kW/hr. The cost of just that one leak would be $2,364 per annum! Now imagine the accumulative cost of multiple leaks in a larger compressed air system‌.. Another cost of compressed air leaks is reduced productivity. Compressed air leaks can cause system pressure to fluctuate. This can cause air-operated 14 | KAESER report
equipment to not perform as intended. Automatic equipment shutdown is a common indicator of this problem. As a leaky compressed air system is already working harder than necessary to meet existing production demands, it is therefore not prepared to take on additional capacity when surges in production and growth occur. Finally maintaining pressure in a leaky compressed air system requires the compressor to run more. More run time means the requirement for more frequent maintenance. More maintenance means more downtime which also further reduces productivity. And, if the system is continually working harder than necessary, it may need replacing sooner therefore meaning reduced equipment life. The culprits So where can leaks be found? Anywhere from the compressor right to the point of use. The more fittings and hoses – the more leaks a system is likely to have. They may occur in poorly installed fittings or in joints that have loosened or degraded over time. They are also likely to occur in the last 9 metres of piping as this is generally the smallest piping and hose size and gets the most vibration and stress from the point of use. Some other problem areas include; condensate
Compressed air leaks 101
traps, shut-off valves, fittings and pipe joints, filters, regulators and lubricators to name only a few. Unfortunately many compressed air users accept that compressed air leaks are just an unavoidable byproduct of running a compressed air system. However unmanaged, the costs of compressed air leaks can really start to add up – especially when you factor in the heightened electricity prices we all now face. While it may be unrealistic to eliminate all leaks, it’s not actually that hard to greatly reduce them and identifying and fixing leaks could really have a significant impact on the bottom line.
How to detect compressed air leaks While it may not be realistic to eliminate all leaks, it’s not actually that hard to greatly reduce them. There are 3 main ways you can detect leaks: 1. Listen; A basic method is to listen for the hissing sound that leaks will make. However this requires being able to hear such noises above the sound of plant equipment. It may only therefore be possible to hear larger leaks. As you will not be able to hear all leaks, this method is far from comprehensive.
Leak Detector (USLD). An USLD kit consists of directional microphones, amplifiers, and audio filters. The auditor also usually has earphones to help identify the leaks. As ultrasonic is a high frequency signal, the sound from a compressed air leak is both directional and localised to the source. This allows the detector to sense and therefore locate the source of the leak. Fast and accurate, a USLD is the most versatile form of leak detection and can detect leaks as small as a pinhole. It can be performed while the plant is running as background noise will not interfere with the results. In addition no physical contact with the leaks are required. How to fix compressed air leaks Once you have detected the air leaks the next step is to tag them – preferably with a bright and durable tag - so they can be easily found when it comes time to fix them. Information on each tag should also be logged in a spreadsheet including; location, cost of leak, potential cost savings of fixing the leak and so on. You can then prioritise the order in which leaks are fixed.
2. Soapy water; Alternatively you could apply soapy water to suspected leaks. If a leak exists then soap bubbles will form. Whilst this may be more reliable than simply listening for leaks, it is time consuming and requires that you have physical access to the entire piping system. Another drawback of this method is you have no information on the relative volume of a leak. You can therefore not make any decision on which leaks are wasting the most air and require immediate attention. 3. Ultrasonic Leak Detection; The most accurate and comprehensive way to detect leaks is with an Ultrasonic
Believe it or not a number of companies will go to the efforts of undergoing a leak audit and then fail to action the findings. Without the follow-up, leak detection will become just another cost. The good news to consider is that the 80-20 Pareto Principle applies. By even just fixing 20% of the leaks, it is possible to reduce the total compressed air leakage by 80% or more. Continual improvement Unfortunately leak detection and repair cannot ever be a one off event. As the compressed air system ages or changes with time it may need further attention. If you want long term results then you must consider leak detection and repair as an ongoing programme. The easiest way to ensure leak detection is not forgotten is to develop a continual improvement programme. As part of this you may consider speaking to your service provider about adding leak detection to your maintenance programme. An ongoing leak detection audit and repair program will quickly pay for itself through energy savings. And, as an aside, you will likely also benefit from reduced downtime and better running production equipment. McCorkle, M. Kaeser Compressors (January 2018): Compressed air system leaks
*
KAESER report | 15
Efficiently meeting fluctuating compressed air demand at Prowler Proof
Securing an
energy efficient
compressed air supply
Over 25 years of reliable service from KAESER has led premium Australian security door and window screens manufacturer Prowler Proof, to opt for a KAESER ASD SFC SIGMA frequency controlled rotary screw compressor, to energy efficiently meet its ‘World Class’ manufacturing facilities increased demand for compressed air. Security, natural ventilation, UV and insect protection as well as protecting from the risk of bushfires - these are just some of the many reasons that numerous buildings throughout Australia are equipped with security window and door screens. Prowler Proof has been manufacturing premium security door and window screens to meet this myriad of requirements since 1984. Remaining proudly Australian owned and made, they deliver the highest performing doors and screens in Australia thanks to a manufacturing process which includes welding the security door and window screens, making them stronger than any screw or rivet.
16 | KAESER report
All Prowler Proof door and window screens are manufactured in the company’s hi-tech fully automated facility in Banyo, Queensland – which is also currently Australia’s only ‘World Class’ manufacturing facility*. Compressed air is used extensively within the manufacturing facility to power a vast range of machinery, including cutting machinery and the powder coat line. As all window and door screens are custom made to fit and manufactured to order with the industry’s shortest lead time, operating a reliable compressed air system is essential to the manufacturing process. Having recently scaled up production it became apparent that the existing 15 year old KAESER
KAESER report | 17
'We picked the ASD SFC to manage our seasonal production cycles and for optimum energy efficiency'
compressed air system was struggling to meet the new demand for compressed air. Michael Henry, Managing Director at Prowler Proof, therefore contacted long standing compressed air partner KAESER Compressors for a solution. After reviewing Prowler Proof’s current compressed air system, the increased demand for compressed air and factoring in the company’s seasonal production cycles, KAESER recommended replacing the existing compressed air system with an ASD 60 SFC SIGMA frequency controlled rotary screw compressor. The ASD SFC series from KAESER deliver premium quality compressed air and superior efficiency, saving energy in multiple ways: The latest release of the ASD SFC series of SIGMA frequency controlled rotary screw compressors incorporate a completely new and innovative drive technology. Representing a significant technological milestone for KAESER, the new synchronous reluctance motors - which were developed in close partnership with Siemens - boast significantly greater efficiency, thanks to considerably lower losses in the crucial partial-load range compared to asynchronous motors. The low moment of inertia of synchronous reluctance motors allows high cycle rates, thereby boosting machine and system productivity.
18 | KAESER report
Some of the technical advantages of the new motor design include near zero heat losses from the rotors, which keeps bearing temperatures noticeably lower. This in turn has a positive effect on service life, ease of maintenance, as well as drive availability. Moreover, KAESER’s use of variable-speed fans in compressed air production systems delivers additional energy savings. The major advantage of this complete solution is that it delivers efficiency gains of up to ten percent in the partialload range compared with conventional variable speed systems. This ensures minimal energy consumption and minimal operating costs particularly where compressed air demand fluctuates as is the case at Prowler Proof due to seasonal production cycles. In addition, the compressor is controlled and monitored via the industrial-PCbased SIGMA CONTROL 2 internal compressor controller. The flow rate can be adjusted within the control range according to pressure. Operating pressure is kept constant to within ±0.1 bar. This allows maximum pressure to be reduced, which, in turn, leads to significant energy and cost savings. Not only do these optimised compressors deliver more compressed air for less energy, but they also combine ease of maintenance in an environmentally
responsible design. Prowler Proof recognises the importance of protecting the environment and therefore considers all aspects of the manufacturing process to ensure minimal impact on the environment. This was therefore a key consideration when selecting the new compressor. Michael Henry concluded: ‘We picked the ASD SFC this time to better manage our seasonal production cycles and for optimum energy efficiency. KAESER has been our compressed air supplier now for over 25 years and we have been extremely pleased with the KAESER equipment which has worked reliably all that time! Another big reason we continue to choose KAESER is the service we have received. KAESER is always reliable and the addition of the oil testing and analysis at service visits on the old compressor, has given us the extra confidence over the years that everything was in good working order.’ Prowler Proof has achieved the rating ‘World Class’ on the PROBE Manufacturing global benchmark. PROBE is one of the world’s leading organisational assessment and best practice bench marking tools, used in over 30 countries to promote and support the pursuit of Business Excellence across all sectors. The process compiles a report and provides a ‘World Class’ score compared against a cross-section of international companies.
*
KAESER 100
Celebrating years! This year marks the centenary of KAESER Kompressoren. Worldwide it has been a year of celebrations, and here are just a few highlights of how we have been celebrating... A recipe for success! Every birthday needs a cake! And in our case our board members, Tina-Maria Vlantoussi-Kaeser and Thomas Kaeser baked many small cakes for all employees worldwide. In the traditional rooms of the Coburg court supplier Feyler, unique cherry gingerbreads were created based on an innovative recipe. Specially developed for KAESER! Diligent hands wrapped the finished birthday gingerbreads and sent them all over the world.
#kaeserfamily K A E S E R employs in excess of 6,000 staff worldwide, and all staff are considered family! The extremely long service record of many of our employees is truly testament to that fact, with a number of them having been with KAESER for more than 30 years. We recently got some of our KAESER Australia team together for a special photoshoot to celebrate the 100 year anniversary.
Open Day In July, KAESER opened the doors of its state-of-the-art manufacturing facility in Coburg, Germany to the public. The Open Day presented an opportunity for visitors to look behind the scenes at KAESER.
Family celebration At the head office in Coburg, Germany staff were invited to attend a special 100 year celebration. One of the car parks was turned into a festival ground for the occasion, where staff and their families raised a glass to the 100 years of our past – and to the next century of our future!
KAESER report | 19
KAESER COMPRESSORS Australia Pty. Ltd. Locked Bag 1406 - Dandenong South - VIC 3164 45 Zenith Road - Dandenong - VIC 3175 Phone: +61 3 9791 5999 - Fax: +61 3 9791 5733 https://au.kaeser.com - E-mail: info.australia@kaeser.com
MOBILAIR M 255E up to 24.7 m3/min Mega-power with electric drive Maximum energy efficiency
e-power
wherever an electrical power connection is available. Exhaustfree and silent compressed air production
with the super-premium efficiency IE4 electric motor
Outdoor installation
the entire system is designed for outdoor installation
Simple operation
with the SIGMA CONTROL SMART controller
Low maintenance cost
Multiple applications
from temporary use in industry to handling peak production periods to permanent outdoor installations
significantly lower maintenance costs compared to diesel-powered machines
KAESER - More compressed air and more savings