Case study: metal fabrication company reduces costs with Kaeser

When Kaeser got involved, this metal fabrication company went from blowing energy costs to reducing them. Thanks to Kaeser Compressors for the use of this case study.

About the company

This growing metal fabrication company was using an older system that seemed too small for its job. The system had unreliable air flow, and energy consumption costs were increasing. Enter Kaeser.

Problem: modulating air flow, bigger energy bills

A precision metal fabricator was spending considerable time and money maintaining their aging compressed air system — time that would be better spent on their business. A 40 hp, modulating control compressor supplied the flow, but problems with downtime had them looking for a more reliable solution. Additionally, even with their back-up 40 hp unit, system pressure fluctuations caused frequent disruptions to their compressed air supply, impacting reliability at the point-of-use and left them wondering if their compressor was undersized.

Solution: dual control compressor

A comprehensive Air Demand Analysis (ADA) revealed that the modulating compressor was actually oversized in a big way. The compressor was running on average at only 30% capacity and couldn’t respond to the system-wide pressure fluctuations — all the while consuming nearly full power and racking up their energy and maintenance bills. A single 20 hp dual control compressor could reliably supply the flow and keep energy costs low. And to make it even easier, authorized Kaeser technicians could handle the installation and all annual maintenance.

Results: reliability and energy cost savings

The 20 hp compressor has reduced their energy costs by 40% — even though growth has increased their average demand by 20%. The second 20 hp compressor provides complete redundancy and with the two compressors splitting the load, maintenance costs have also been cut. They no longer have to continually monitor the system for pressure drops or worry about disruptions in their compressed air supply. This new split system was just the solution they were looking for.
  • Specific power of previous system: 48.09 kW/100 cfm
  • Specific power of new system: 22.47 kW/100 cfm
  • Annual energy costs of previous system: $19,716
  • Annual energy cost savings: $7,958
  • Utility rebate: $6,680
  • Total first year savings: $14,638
  • Simple payback period: 1.8 years

Compressed air assistance

Elevated Industrial Solutions is ready to help with ADAs and analysis. Contact us for service if you’re in the Detroit, Flint, Ann Arbor, Toledo, Dayton, Cincinnati, or South Carolina areas.

Interest rates forecast + construction and manufacturing

Interest rates vary by industry, lender, borrower, loan type, etc. However, almost all interest rates are affected by the Federal Reserve, which sets the rate that banks use to lend money to each other. This rate is known as the “fed fund rate,” and it influences all other loans. 

So while the Federal Reserve doesn’t have direct control over, say, mortgage or auto-loan interest rates, their decisions wield a strong influence. 

The Federal Reserve has two specific goals: increasing employment and creating stable, affordable prices. They attempt these objectives by changing rates to fit specific situations. When the market is seeing rapid inflation, it’s often because overall demand for products and services is too high. To ease this demand, they may increase rates and try to cool the market. However, if the market is stagnant, they may lower rates, which would (in theory) stimulate economic activity and overall demand. 

(This, we admit, is a far-too-simple explanation of the Federal Reserve and interest rates.) 

Decisions made by the Federal Reserve have a massive impact on many industries, including manufacturing and construction. If you work in these industries, it helps to understand what the Federal Reserve will do, why it will do it, and what impact it will have on your business.

Interest rates forecast

When inflation was running wild, the Federal Reserve attempted to cool the market by increasing interest rates. It was believed that by reducing rates, overall demand would be tempered. Using the supply-demand principle of basic economics, it was hoped that by making it more expensive to borrow money, people would start purchasing less, reducing demand and stopping runaway inflation. 

Since the summer of 2023, interest rates have been kept around 5.5%, which is higher than the levels from the previous ten years. But, with inflation cooling, it appears the Federal Reserve is now open to lowering interest rates. Already, the Fed has telegraphed that rates will be cut as early as September

According to a Morningstar report, Fed officials are expected to “deliver hefty cuts” over the next few years. The Federal Reserve rate could drop to 1.75% by the end of 2026. 

The Federal Reserve Bank of St. Louis is making a similar prediction. Their forecast chart calls for interest rates to drop to 4.1% in 2025 and 3.1% by 2026. 

So, by almost all accounts, interest rates will drop. But what will this mean for your industry?

Lower interest rates: the impact on manufacturing

Whether manufacturers produce massive equipment or small components, they are impacted by interest rates. Demand for their products will fluctuate quickly after interest-rate hikes are announced, as buyers try to make purchases before the increases take effect. When high rates are in play, consumers and businesses often reconsider large purchases. 

High interest rates have clear implications for manufacturers producing large, expensive products. However, the impact also affects makers of small parts and components, who rely on orders from larger manufacturers. The components they produce may not be expensive, but demand for the final product could decline when interest rates are high. 

Alternately, when interest rates are low, manufacturing companies experience high demand. It is far more affordable for customers to borrow money, which means large-scale orders, often totaling millions of dollars, can be reduced by tens of thousands. 

With an expectation for lower interest rates in the next few years, customers may delay their orders. Instead of ordering now, they may wait a year or two, expecting that by mid-year 2025 or 2026, the cost of borrowing will be much lower. Potentially, this could create a lull for the remainder of the year and a rapid increase in activity once low interest rates are in action. 

Lower interest rates: the impact on construction 

The construction industry, whether it’s traditional construction or offsite construction (also known as modular), has a unique, two-fold relationship to interest rates. Builders are directly impacted by interest rates, as they often borrow money for materials, tools, and development property. The industry also relies on a consumer base that is heavily influenced by interest rates. Construction (particularly residential) needs homebuyers, but with high interest rates, consumers hesitate to buy homes. 

Recently, the construction industry has struggled to maintain growth, although total output remains relatively high. Throughout most of 2022, roughly 1.6 to 1.7 million privately owned housing units were under construction, according to the Federal Reserve Bank of St. Louis. The number has stayed steady, but it has dropped over the past year, from nearly 1.7 million to under 1.6 million. 

According to a report from Bluebeam, a construction software company, “higher interest rates have completely frozen the owner-occupied residential construction market.” However, if rates come down, as expected, we could see increased demand for new construction. 

Lower interest rates could also create more demand in commercial construction. High rates create a barrier in commercial building, which has projects that are far more expensive (typically) than residential building. With lower interest rates, we could see refreshed activity in commercial construction.

Reduce your impact with Elevated

No matter what the future holds, Elevated Industrial Solutions can be your partner in the manufacturing and construction industries. We understand the needs of dynamic companies like yours, helping you make the right decisions about your company, its processes, and more. Our solutions include coating and finishing, industrial supplies, compressed air systems and services, and assembly tools and services.

What to do about high and low compressed air temperatures

Summer can be fun — BBQs, pool parties, ice cream, and more. But facilities managers believe summer can be stressful, too. High ambient temperatures, the source of so much summer fun, can impact the overall performance of an air compressor system.

But it’s not just summer that’s a problem. Extremely low ambient temperatures, especially when they approach freezing, can also impact compressor systems.

Why air temperature matters

Higher ambient temperatures influence the amount of moisture in the system. When the air is 95 degrees Fahrenheit, for example, it holds roughly 230% more moisture than when it’s around 65 to 70 degrees. This means more moisture in the system, impacting tool performance and internal air quality.

Most air compressors must maintain an internal temperature of roughly 50 to 100 degrees. When air is extremely cold or too hot, performance lags. They can overheat or, when too cold, freeze and stop functioning, which can damage internal parts. Also, many systems rely on ambient air to stay cool. When temperatures are hot, staying cool becomes increasingly difficult.

Key factors

Altitude and “volumetric flow”

Air compressors are designed to operate at a specific volumetric airflow. However, changes in altitude will impact this air flow; the higher the altitude, the less air flows into the system. Therefore, more volumetric flow is needed to achieve the best results. We won’t bog you down with the physics and math; just know that if your facility is at a higher altitude (Denver or Albuquerque, as examples), you’ll need a stronger air compressor to achieve the same results than at close to sea level (Detroit).

Cooling methods

The cooling method for an air compressor is a significant design choice. Air-cooled compressors and dryers need thousands of cubic feet per minute of cooling air to maintain ideal operating temperatures. It all depends on the size of the system, but if your compressor room can’t bring in enough air, it may struggle to maintain performance.

If air temperatures often exceed operating temperature, you may need a water-cooled system. For instance, if your facility is in Arizona, South Carolina, Georgia, etc. where summer temperatures constantly surpass 100 degrees, the air won’t cool the compressors. (At least, not as effectively.) Therefore, a water-controlled system may be ideal.

Dirty or dusty environments

High temperatures often bring dusty conditions, which places more strain on the system. When the compressed air system operates in a dusty environment, the service intervals need to be shortened to reduce the chances of overheating, excessive operation, and low airflow. Motor greasing should be a priority, as friction can cause greater harm to the system. If your environment is dusty, take additional steps to maintain your compressors, especially when temperatures are hot.

Keeping your system cool in hot temperatures

Proper placement

Having an air compressor in the right place is critical. If you stack multiple compressors next to each other in an area with numerous other machines, they may struggle to keep a cool internal temperature. Like multiple people in a crowded room, air compressors like having enough space to stay cool and comfortable.

Ventilation

This is directly connected to compressor placement. These machines need good ventilation to work properly. Placing them where they receive enough airflow is important, and adding fans and other air-movement and ventilation sources can help. Open windows and large fans can help a compressor with ventilation.

Appropriate size

Smaller air compressors have to work harder to reach the same air volume as a larger system. This extra work can result in higher temperatures. While other factors are at play, if your system is constantly overheating, a larger compressor may be required. If a larger compressor is not possible, an additional compressor of the same size could help.

Monitoring

When it comes to keeping the system cool, diligence is key. Knowing how the system runs can make a big difference in understanding and managing the compressors. Monitoring key points, such as the compressor, dryer, and overall system, will indicate how well or poorly the components are running. Monitor information like discharge temperature, motor temperature, and system pressure so you are fully informed about what happens within the compressed air system.

Maintenance

Keep up with maintenance throughout summer (and all seasons, for that matter). Scheduled routine maintenance ensures your compressor runs better and is ready for higher ambient temperatures.

Should you purchase a water-cooled compressor?

Installing a water-cooled system is one of the most effective ways to deal with high ambient temperatures. Multiple types of water cooling are available, and they help maintain compressor discharge temperatures.

However, these systems have a higher overall cost. While the initial capital is not huge (compared to an air-cooled system), the operating costs are higher. The costs of running a water-cooled system can exceed $100,000 annually (see “Water-cooled Air Compressors”), while air-cooled systems are often less than $10,000 to operate. There is an additional expense if a cooling tower or chiller system needs to be added.

Design, installation, and service for your entire system

Proper installation is crucial for maintaining compressed air temperatures. Work with the industrial experts at Elevated Industrial Solutions, and we’ll ensure you have a system designed to handle years of hot (and cold) ambient temperatures!

From scorching summers to frigid winters, we can provide a compressed air system from Kaeser or help your current compressed air system.

Save money on your compressed air systems

Depending on the size and scope of a factory, assembly plant, or manufacturing facility, the energy bill could be over $10 million a year. For some facilities, an energy bill of $1 million isn’t unheard of.

Typically, a large portion of this bill comes from air compressors. The Department of Energy estimated that compressed air could account for roughly 10% of electricity consumed at a facility. For some locations, it could be as high as 30%.

According to a scientific review conducted by Malaysian researchers, “Only about 10–20% of total input energy is utilized for useful work in compressed-air system.” This means for every $1,000 spent on compressed-air energy, only $100 to $200 is actually used to power machines and tools.

The numbers can be complex, but the overall point is simple: running an air compressor is expensive. Therefore, you have to get the most from your system. There are many strategies for compressed air savings, including rebates and incentives from state governments.

1. Work with the right installer

Arguably, the most important step, as it impacts all other factors, is that a facility must work with the right installer to bring the highest compressed air savings. An experienced, trained, and knowledgeable compressed air installer can examine your air needs and make quality recommendations to ensure the best results. If needed, they can conduct a thorough audit of your current system.

An air systems installer can work directly with a plant manager and ownership team to make strategic recommendations and ensure successful installation. They can suggest proper equipment for longer lasting energy savings as well as design and install a system that provides maximum efficiency. Installers, especially those who have worked in your industry, will recommend the best placement for air drops, the proper size and number of air compressors, and will consider the cost and value of your system.

Also, an installation professional can recommend changes and custom engineering solutions, helping facilities overcome barriers to efficiency, such as dirty environments or complex facility layouts.

2. Ensure you have the right machines

Before a facility can begin maintenance and apply for rebates, it needs the right equipment. Proper air compressors and accessories from leading manufacturers will ensure a higher level of success, bringing better efficiency and lower costs.

The air compressors should properly match your operations. Each facility has different needs for compressed air; some only need one small air compressor, while others need multiple large-scale machines. The distance from the compressor to the use point, as well as the number of drops and types of tools in regular use, will all impact your compressor selection.

The air system, from compressor to tool, should properly match your needs. It must have the right horsepower and deliver proper cubic feet per minute (CFM) to ensure efficient air use.

Compressed air savings start with the right compressor from high-quality manufacturers like Kaeser.

3. Keep up with maintenance

Maintenance matters. Industrial facilities need proper maintenance for their compressed air systems. Maintenance uncovers issues that may cause your facility to shut down and provides opportunities to make immediate changes to run at peak efficiency.

What will a service team do? They’ll change air and oil filters, add lubricant, replace belts, inspect vents, and more. After all, preserving your compressed air system keeps costs down.

4. See your state’s energy rebates

All states, from California to Maine, provide energy rebates and incentives to private individuals and organizations. When considering energy savings, it helps to look up various incentives, especially when installing new equipment, as many programs make energy-efficient installations more affordable. Some offer down-the-road savings through tax incentives (in other words, pay for the expense now, get a big reduction on your taxes later), while others provide more immediate savings or favorable loan terms. The right compressed air service team will know these rebates well.

The Database of State Incentives for Renewables & Efficiency is among the best resources. This website enables you to find excellent rebates by searching an interactive map. You can select a state and search categories that include biomass, fuel cells, geothermal, and emerging technologies. There is also an energy-efficiency category.

There are numerous incentives for every state. Let’s look at a handful of examples from a few states.

South Carolina

In South Carolina, various programs bring financial incentives and favorable loans for energy-efficient upgrades and installations. For example, there is the Energy Efficiency Revolving Loan Fund, which provides up to $1 million for energy upgrades to commercial and industrial groups.

Ohio

Some areas provide local incentives. Cincinnati, Ohio, provides a good example. They have the Property Tax Abatement for Green Buildings program, which allows for a temporary tax abatement on commercial properties that meet LEED certification standards. This allows for a 15-year tax abatement.

Michigan

In Michigan, manufacturing facilities can take advantage of financial incentives that include the Coldwater Board of Public Utilities rebate program. This program encompasses numerous energy-efficient changes that may not be related to your air system but allow for a reduction in your energy bill. This program includes compressed air systems as well!

Call us for compressed air savings!

When it comes to the right installations, ensuring fantastic maintenance, and getting the equipment, the Elevated team can help. We make facilities more efficient, use less energy, and receive money-saving incentives and rebates! Our team will never sell compressed air systems you don’t need. And with 24/7 emergency coverage, we’re here to help you get your facility running at peak performance.

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

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!

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