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Compressed air is a critical utility for automotive assembly plant and parts manufacturers. It also represents a large portion of the energy footprint in those plants. A reliable system is necessary but can also be provided efficiently, minimizing the carbon footprint. Whether it be in Stamping, Paint, Engine Assembly or Final Assembly, an unstable system can lead to issues with the final product quality.
A large automotive assembly plant with over 12000 HP of compressors was looking to reduce their carbon footprint. They were also in the midst of a major expansion and needed to match ensure they could supply the compressed air reliability. The Paint Dept, Stamping Dept and Assembly all needed a different pressure to operate properly. A system audit was performed to identify the system capability and outline the optimal system for the future. The project happened in phases. New AirLogix PLC Controls were installed on 5 Centrifugal compressors in one building, Three new AirLogix PD were installed on three rotary compressors in another building and a centralized AirMaster system was implemented. All of the control was done to automated pressure regulation to each of the manufacturing area of the plant. That way each area could utilize on the pressure needed and reduce artificial demand.
A large automotive assembly plant had five existing 1200 HP Centrifugal compressors and one rotary screw. They were undergoing a major expansion. They were going to add two more centrifugal compressors to the system. They wanted to get better control of the compressed air system. New AirLogix control systems were installed on the existing centrifugal compressors. They also purchased new centrifugal compressors with AirLogix controllers. The compressors were installed in two major manufacturing areas of the plant, but tied together via a common header. A new AirMaster automation system was implemented and all of the compressors were integrated over the plant network. Load sharing of the compressors was implemented resulting in an excess of 7MM lb of carbon reduction.
A large automotive engine plant was looking for implementation of master controls for the compressed air system to reduce the carbon footprint. They implemented CaseiZ AirMaster as the central controller. They also implemented AirLogix controllers with Air Density compensation to help reduce compressor blowoff. One key aspect of the system was to implement a boosted storage system to ride through peak demands during shift changes and meal time. This prevented compressors from cycling on for short periods of times improved overall efficiency. Peak demand management was also implemented to prevent large demand charges from the utility company.