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compressed air case study about sustainability

Case study: reducing energy waste to improve efficiency, save money, and increase sustainability

Written by Christopher Richmann on April 5, 2024. Posted in Coating application equipment, Compressed Air, Compressed Air, Compressed Air, Compressed Air, Featured, Manufacturing, Metalworking. Leave a Comment

When Sandvik Coromant laid out ambitious goals for sustainability and energy efficiency, they realized that the air system in their South Carolina facility needed an upgrade. Working with Elevated Industrial Solutions, they were able to cut waste and enhance sustainable practices, all while reducing their overall energy bills.

About the client: Sandvik Coromant

Sandvik Coromant is a manufacturer specializing in metal-cutting tools used in machining applications. Established in 1942 in Sweden, this company is part of the larger engineering group known as Sandvik.

It’s an impressive company with over 100,000 customers worldwide. Sandvik holds more than 1,700 global patents and files 150 patents each year. The group specializes in customized machining tools and digitization; in manufacturing circles they have a well-established reputation for fast production and lasting quality.

As a major global company, Sandvik Coromant leaders are aware of their significant impact on the environment. They are committed to sustainability and energy efficiency, which is why they needed the support of our air-system experts.

The problem: wasted energy from the air system

Sandvik Coromant grew in numerous global regions, including South Carolina, mainly at the Westminster facility.

The existing air system in Westminster had some issues. It was outdated and decentralized, leading to poor energy efficiency and overall air loss, causing the compressors to work overtime to meet the facility’s air needs. There was an issue maintaining consistent pressure, especially when the workload increased. The air within the system also had quality issues, reducing overall product quality and creating further needs for equipment maintenance.

Energy consumption was a particular issue for the facility. Previous studies indicated that the air system was one of the biggest energy users for the entire facility. The company, however, had bold targets for sustainability; wasting that much energy was unacceptable.

Sandvik Coromant needed a partner who could evaluate their needs, plan and build an efficient system, and work with the company to maintain reliability, efficiency, and overall performance. They turned to Elevated, an authorized Kaeser distributor in the South Carolina area, to overhaul the air system and provide greater efficiency with superior performance.

Our solution: a smart, innovative air system

Using an air-study process, Elevated recommended a new primary air system and a smaller secondary system.

The primary system would consist of four DSD-175 rotary-screw compressors and three TG 980 Secotec dryers. The team would also install a Sigma Air Manager (SAM) 4.0, which pulls operational data and enables stable pressure. To enhance efficiency, the team recommended increased storage and a new SmartPipe distribution system. These components and technologies would improve overall efficiency while significantly reducing wasted air.

The secondary system would be used for extra machining and would consist of two SK 20 rotary-screw compressors. There would be a SAM for this system as well.

The result: sustainability, savings, and efficiency

The original study estimated roughly $80,000 in annual energy savings for the facility. Even for a global manufacturing group like Sandvik, this would be a significant improvement. But in the end, the savings were $90,000 per year – $10,000 more than anticipated.

In addition, facility managers can track usage and make adjustments thanks to reporting capabilities by the SAM unit. Using this critical information, managers and leaders can decrease pressure – as needed – for additional savings, all while delivering on the company’s promise to be more efficient and sustainable.

Exceed your goals with Elevated

Elevated helps you meet your company’s goals. We can increase the efficiency of your facility in eastern Michigan, western Ohio, and South Carolina. Our expert teams can install machines, conduct analysis, and provide additional equipment … just like they did at Sandvik Coromant.

We also offer preventive maintenance at each of our locations to ensure your facility never shuts down, operating at peak efficiency every day.

Special thanks to Kaeser for the article write-up!

All about 3M

Written by Christopher Richmann on March 20, 2024. Posted in Abrasives, Adhesives, Aerospace & defense, Automotive, Brands, Construction, Industrial supplies, Manufacturing, Metalworking, Tapes, Woodworking. Leave a Comment

3M is an American corporation that manufactures and distributes industrial, home, and office supplies. It was originally named the Minnesota Mining and Manufacturing Company. Today “3M” is the official and legal name of the company.

Headquartered in St. Paul’s suburb of Maplewood, this innovative company’s employees create products for many industries, including construction, aerospace, defense, metal fabrication, woodworking, countertop fabrication, manufacturing, and healthcare.

A long history of innovation

3M was founded in Two Harbors, Minnesota, which rests on the northern shore of Lake Superior in northern Minnesota in 1902. Dr. J. Danley Budd, Henry. S. Bryan, William A. McGonagle, John Dwan, and Hermon W. Cable are credited with having founded the company together.

Since its inception, the company has revolutionized sandpaper, developed masking tape (something we take for granted these days), mass-distributed sticky notes, and created a product to protect fabrics. The team also helped launch new products to help in the war effort during WW II.

During COVID, the company’s personal protective equipment (PPE) was in high demand. Healthcare workers and first responders were given priority as they dealt with patients and those needing care. To help more people and the government, the company ramped up production to save more lives.

Well-known brands

3M brands are quite literally household names. Any time you grab a piece of tape, chances are good it’s Scotch tape. When you add a sticky note to save information on your book, you might be grabbing a Post-it note. 3M owns more than 30 brands, including Scotch, Scotch-Brite, Scotchgard, and Post-it.

A vast array of products

3M currently offers a vast assortment of products — more than 60,000 — while serving numerous industries. Their products include:

Abrasives
Adhesives
Building materials
Coatings
Coating and finishing spray equipment
Polishes
Electrical supplies
Sheeting
Insulation
Lubricants
Medical supplies
Signage and marking materials
Tapes

They literally provide everything from dental aligners to items to make semiconductors. 3M literally has it all.

Our highlights

It’s impossible to name every product, but we can highlight a few of our favorites ….

Green masking tape

Extremely popular, 3M Green Masking Tape is a product built on durable yet easy-to-use crepe paper, which allows for swift and accurate tearing. This UV-resistant tape was designed specifically for high sunlight exposure; it’s ideal for outdoor paint masking, temporary use on outdoor signs, and protecting various items during paint and construction projects. It also serves in many capacities as regular tape.

Our customers love it for its ease of use, versatility, durability, and affordability.

Xtract sanding system

Sanding is an important phase for various manufacturing processes. 3M has created “clean sanding” with the Xtract sanding system, which enhances product surfaces while creating a clean working environment. The system uses extraction holes throughout the sanding surface to remove 99% of all dust, resulting in a cleaner work environment without sacrificing product quality.

It’s a great solution to prevent dust from impacting your workforce’s health.

VHB tape

Standing for “Very High Bond,” 3M’s VHB tape is a two-sided adhesive that has been serving users since 1980. It was originally used to secure panels to ambulance frames, a clear demonstration of this product’s incredible bonding strength. The tape is now used in numerous automotive, furniture, and industrial applications.

Performance Industrial Spray Gun HVLP System – (26878)

This durable system was built for industrial painters. It’s lightweight, making it easy to carry and ensuring a consistent spray. The spray gun’s trigger was optimized by kinesiologists to increase ease of use, preventing hands from getting tired and impacting a finish. This system is also versatile, spraying from a pressurized source or a gravity cup. Adding to its versatility, replaceable nozzles enable you to change sprays and make clean-up easier.

Proud distributor of our partner

Didn’t see your favorite product on our list? Don’t worry. Elevated has a full range of 3M products for virtually every industry.

We take pride in providing 3M and other high-quality brands. We supply solutions that help your business be more efficient and effective, including saving time, reducing overall costs, improving productivity, increasing quality, etc. Your goals are ours. It’s why we call ourselves your partner.

Of course, if your heart is set on a specific brand, such as 3M, we won’t turn you down. 3M acts as our partner to help train your staff and get the best product possible at a reasonable cost.

Elevated Industrial Solutions Launches Two New Products, Elevated Thick and Elevated Thin, for the Countertop Fabrication and Installation Industry

Written by Tami Matthews on March 12, 2024. Posted in Adhesives, Brands, Countertop, Industrial, Industrial supplies. Leave a Comment

DENVER – March 12, 2024 – Elevated Industrial Solutions (“Elevated”) is proud to announce the creation and release of two new products: Elevated Thick and Elevated Thin countertop seaming adhesive. These two new products add to Elevated’s wide array of premier brands available to the countertop fabrication and installation industry. Thick and Thin are the first Elevated products the company has ever launched.

Brad Zotti, president of Elevated, said, “We’re excited about launching our own products! After listening to our countertop fabrication and installation customers and reviewing product offerings, we knew this market needed more options when it came to countertop seam adhesives.”

Craig Miller, Director of Industrial Solutions, commented. “We’re thrilled to suggest two more solutions Thick and Thin. These two adhesives stand up to every rival while being super affordable. It’s a great value and customers are already loving it!”

Thick and Thin are available across the United States, seaming every solid surface and natural stone available. Thin and Thick come in core colors and are perfect for a variety of countertop fabrication and installation jobs. Because Elevated has warehouses and offices across the nation, the two products can be delivered to most locations in two days.

For more information about Thick and Thin, as well as information on how to order, visit: https://elevatedindustrial.com/thick-and-thin/

About Elevated

With headquarters in Denver, Colorado, Elevated serves customers through its offices and warehouses across the nation – Colorado, Wisconsin, Ohio, South Carolina, and Michigan as well as sales offices in Montana and California. Nationwide, Elevated offers industrial supplies, coating and finishing systems, and assembly tools. In South Carolina, western Ohio, and eastern Michigan, Elevated also provides compressed air systems and services.

Contact us

For media inquiries, contact:

Tami Matthews, Marketing Director
503.803.3682
tmatthews@elevatedindustrial.com

How to find the right compressed air systems installer

Written by Christopher Richmann on February 14, 2024. Posted in Air compressors, Compressed Air, Manufacturing. Leave a Comment

Compressed air is a critical part of your industrial facility. Powering pneumatic tools, operating machines, and even filling tires, the compressed air system enables your facility to thrive and produce.

Whether you have decided to replace your existing system, upgrade, or expand to accommodate more production at your facility, you must work with the right installation team.

The right installer is equipped and experienced so they can meet your exact needs. They’re familiar with your type of facility, meet rigid safety standards, and provide specific services that are ideal for your operation.

Choosing the right air compressor installer may seem complex. But when you consider your specific needs and future goals, you can find a professional who is the ideal fit.

Understands your facility and industry

While the principles of compressed air are fundamentally the same from facility to facility, there are differences in overall type and function. You must find a compressed-air expert who understands your goals and plans.

Are you planning to expand again in the next few years?
What equipment are you running?
What’s in the area (electricity, etc.)?
What do you produce?
Will your system include an outside location?
What’s your timeline?
What’s your budget?
How many staff do you have?
How big is your facility?
What are your goals?

Installers who have been in your industry typically understand what’s expected and may even have photos in a portfolio to show you. They’ll have recommendations of where drops should be, how long the project will take, and more. They may even be able to save you energy … which means saving you money.

Provides maintenance and repairs in emergencies

Eventually, your system is going to need maintenance. It’s easier to get on a schedule as you’re installing and starting up your compressed air system, especially as it helps protect warranties. It’s even better to know who to count on in emergencies — such as sudden issues with your compressed air system. Although Kaeser is known for its quality, even those machines can leave the company with unforeseen problems.

In addition, it’s good to know the company can handle just about any major brand of compressor like the Elevated team can.

Has great references

When you hire a new team member, you ask for references and contact information. You should do the same with your compressed-air installer. These references can come from different industries and specializations, but it’s best if these references are from a similar niche or industry.

For example, if you need air compression for powder-coating operations, it helps if at least one of these references is from the powder-coating industry.

Considers cost savings vs. value

We all need to save money, but it’s important to consider the cost and value of different compressed-air systems. The installer you select should offer competitive pricing, but their services should include money-saving (and money-making) aspects like energy savings, productivity enhancement, and a reduced risk for expensive repairs. For example, Elevated provides various piping to bring down cost without sacrificing quality.

Suggests system audits first

If you’re having a system replaced, some installers recommend you have a complete system audit before removing your current compressed-air system. The U.S. Department of Energy recommends finding an installer who is familiar with assessment services, including walk-through evaluations, system assessments, and system audits. Sometimes, they simply need to add more machines or a different machine.

An audit or just a walk-through could target ways to improve your system, helping to avoid the expensive cost of a new air compression installation.

Handles custom engineering

Sometimes, facilities have constraints, such as a dirty environment or space limitations, that need a different approach: custom custom-engineered solutions. It’s designing an installation approach from scratch, boxed, and ready to be delivered. It’s typically turnkey with little to no assembly required. Everything is built to specifications and tailored to exactly what you need. In return, your facility gets reliability, easier maintenance, and better energy efficiency.

Elevated install teams

Elevated Industrial Solutions is the right installer for a variety of systems. We offer a full host of compressed air services, including system audits, installations, emergency repairs, and preventative maintenance. Our team surveys the site, gets ideas, and discusses needs before putting together a proposal.

But it doesn’t end there. We communicate with your team to ensure they know the details of the project without being overburdened.

Let us help your company meet your air goals.

What do you do when your air line pressure drops?

Written by Eddie Kolinske on February 8, 2024. Posted in Coating & Finish Systems, Coating & finishing systems. Leave a Comment

You’re spraying wood, plastic, metal, or whatever … then suddenly your pressure drops so badly your spray is inconsistent. Maybe the guy next to you mumbles a curse. That’s happened to you, right? Those air line pressure drops and dynamic air pressure readings (where the pressure bounces around) are important, especially when using the air-atomizing settings.

We have a few ideas on what to check.

Do you have the right hose size?

It’s typically a hose size problem. Those losses in pressure occur when there’s an insufficient hose size and quick disconnects are the main culprits.

One factor could be the amount of length and air line travel time. Air line pressure drop is affected by; length of travel, CFM, and air pressure at the source. The chart below illustrates the pressure drop in a 35 ft. hose at various CFM’s and output air pressure.

Pressure drop in 35′ rubber hose
(not including pressure drop from fittings & Q. D.)

	6 cfm @		10 cfm @		15 cfm @
Hose I.D.	125 psi	30 psi	125 psi	30 psi	125 psi	30 psi
1/4″	5	15.7	12	N/A	26.8	N/A
5/16″	1.6	4.9	3.7	11.5	8.9	N/A

We would recommend the more flexible 5/16” air hose up to 25’ when the spray gun requirements are about 10 CFM, and the 3/8” hose for spray gun requirements over 10 CFM and up to 35’.

To set the desired gun incoming pressure without having to pre-determine your actual pressure drop use this technique. Just pull back the gun trigger ¼” so as not to omit fluid, however air is exhausting. Then adjust the air regulator at the other end of the hose to the desired air pressure which we have labeled as dynamic air pressure.

Are your hoses worn?

Give a visual inspection to ensure there aren’t tears or kinks in the hose. Sometimes those can cause pressure drops and may be small enough that you don’t immediately notice.

Is there a problem with the connection?

Cracks in your gun, worn valves, and the like may prevent a good connection between your spray gun and hose, which can cause pressure problems. Visual inspection of your gun and the connectors should help clarify if that’s the case. If it is, we can help you replace those parts.

Is it a compressor problem?

For bigger shops, you may be using an air compressor to help spray projects. The compressor makes a big difference in getting that perfect spray. It could be several things, including needing maintenance. In South Carolina, Michigan, and Ohio, we have compressed air service technicians who can help. They work on all major compressor brands, including Kaeser, Ingersoll Rand, Gardner Denver, Quincy, Sullair, Chicago Pneumatic, and Atlas Copco.

And if you’re really stuck, the entire compressor shutting down and halting production, those locations offer 24/7 service, 365 days out of the year. They’re even working on Christmas.

Contact us!

Although we’re not there, we may have a few ideas and some products to replace compressors, valves, and hoses to ensure you’re spraying perfectly every time.