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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 It was outdated and decentralized, leading to poor energy efficiency and overall air loss, causing the compressors to work overtime to meet the facility’s air needs.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!

Tony Grubish is an MVP at Kaeser and Elevated

Written by Tami Matthews on March 5, 2024. Posted in Compressed Air, Compressed Air, Compressed Air, Compressed air systems, Employees, Featured. Leave a Comment

We love it when we receive updates that demonstrate our employees’ commitment. The story below was covered in February 2024. Now that it’s August 2024, Kaeser just announced the All-Star Leads for who’s winning mid-year. It’s no surprise that Tony Grubish is the mid-year Most Valuable Player. And congratulations to Tom Kilgore for winning Best Batting Average at the mid-year point.

Kaeser Compressors has high standards. The company and its employees only produce quality compressed air systems. Tony Grubish (sales engineer at Air Center – an Elevated Industrial Solutions Company) has high standards, too. Tony won the coveted Most Valuable Player (MVP) award for #1 salesperson in the U.S. from Kaeser (as part of the All Star contest) announced in January 2024.

Kaeser is known for precise German engineering. Like Elevated, Kaeser doesn’t compete on price; the company positions sales around value. What does that mean? The yellow compressors aren’t the cheapest option but are known for their longevity and quality; people choose them for their reliability and trustworthiness.

Tony Grubish came from the U.S. Air Force as a mechanic. Afterward, he worked as a service technician with a major competitor for nine years. At Air Center, he’s spent the past 19 years as a technician, service manager, and now a sales engineer. That time has given Tony a chance to develop a customer-focused strategy – understand his customers’ business and their compressors. In that way, Tony proves he’s reliable and trustworthy. Demonstrating our values is why customers keep coming back.

Kaeser’s All Star contest

There are various rules from Kaeser for the All Star contest based on baseball stats. You need to meet complicated criteria – sell two machines per month and achieve key metrics that include selling specific equipment.

Tony exceeded these metrics, winning the MVP at the year’s midpoint and at the end of the year.

Being an MVP came easy to Tony. One company had a mix of compressors, including some cheap Italian machines, that were failing. Employees there turned to Tony, relying on his expertise and competitive quote. He received a purchase order for 90 units before the end of January 2023.

“I was on a great path,” Tony admitted.

Get the customer, not always the sale

Tony credits his background as a service technician with a Kaeser Master Service Tech/Sales Certification on how he wins with customers. He asks questions to thoroughly understand the customer’s business and checks out the machines. Sometimes, that means he sells a new compressor, but not always. Instead, he’s focused on taking care of the customer to help them meet their goals – recommending service or changes to extend the life of their current compressor … even when he receives a request for quote.

“I’d rather get the customer than a sale.”

He knows he’s building a relationship. Because customers trust Tony, they keep coming back.

Tony said, “Once the relationship is built, selling new equipment, when they need it, is easy.”

Winning

Tony was leading as the best salesperson for Kaeser all year, joined by two other salespeople at Air Center: Chris Brown and Tom Kilgore. Although Chris and Tom lost out in December, our Michigan branch nearly had three of the top five Kaeser sales spots!

He also credits the fantastic service technicians; he indicates they’re a big part of how the branch keeps winning. It doesn’t hurt that his wife, Fay Grubish, is the service manager in northwestern Ohio, where he sells compressors.

“At Air Center, we’ve always taken pride in our service, and we have built a great relationship between our sales and service departments.”

Tony’s win as MVP also moves Air Center to the Kaeser designation of “level 5.” Kaeser has a system of levels from 0 – 5, giving deeper discounts on equipment and parts as you move up the scale. At level 5, Air Center earns more profit from sales. Of course that makes general manager, Jim Casey, happy. It helps their branch stay competitive while selling the gold standard in compressors.

But there were some personal rewards, too, for being the MVP besides bragging rights. Tony and his wife are going to Playa Del Carmen, Mexico. And Elevated provided an extra award for demonstrating the values and brand.

What’s on for 2024?

When asked if he would win the MVP again, Tony sheepishly noted he has a purchase order for a bunch of compressors. Modestly, he confirmed he has a good chance of staying in the Presidents Club in 2025.

That winning attitude is why Tony’s an MVP at Elevated, too.

6 ways to get your facility ready for the holidays

Written by Christopher Richmann on December 1, 2023. Posted in Air compressors, Compressed Air. Leave a Comment

The holidays! It’s a time for family gatherings, gifts, and the time-honored tradition of eating too much, then watching football … or taking a nap.

For many industrial facilities, the holidays often bring lengthy shutdowns and (for most facilities) below-freezing outdoor temperatures. And some shops just choose to shut down so staff can spend more time with family.

If your shop is closing, here are six important tips that will help maintain it from Halloween to Easter and beyond!

Closing the facility? Drain water from the tanks

Water from condensation and moisture can become a serious issue for outdoor tanks. When temperatures drop below freezing, excessive moisture will significantly damage the compressor tank. The tank should have a drain for maximum condensate collection. Some have automatic drains with a test button to ensure proper function.

Removing moisture is important throughout the year, but it’s critical when temperatures drop below freezing.

Winterize drain lines and bowls

Drain lines that are exposed to outdoor air need to be fully winterized to keep them from freezing. Heat trace tape is one of the best ways to keep the pipes warm throughout the winter months. Remember to keep power supplied to the heat trace tape so they can do their job all winter long. (This is especially important if you will be closing shop for the holidays. You may cut power in some areas but keep energy supplied to the tape!)

Adjust compressor louvers

Many air compressors have louvers on the cooling air inlet and compressor outlet. These louvers moderate the flow of air into and out of the unit. If freezing air comes into the compressor, it needs to reach operating temperature as soon as possible. Also, warm air leaving the compressor can be reused to keep the compressor running at ideal temperatures.

While you can check and adjust as needed, it’s best to have automatic louvers that are controlled by temperature sensors. This ensures nearly instant adjustment of your system so the incoming air is utilized properly.

Recirculate air

We discussed the air coming in, but what about the air going out? Air compressors produce warm air. In the summertime, this air is usually vented out, but in winter, facilities can recapture this warm air and use it to heat adjacent rooms (reducing energy costs) or maintain the compressor temperatures.

Use ambient heaters

Compressors can be equipped with optional cabinet heaters to heat and maintain proper lubricant temperatures. If a cabinet heater is not an option, you can use an ambient heater, which keeps the lubricant in the right temperature range. This is especially important to prevent cold starts, which are hard on the system and can result in damage.

Have someone available for emergencies

Perhaps the most important part of your facility prep, you must have someone available at all times for emergency responses and repairs. As we have shown, many potential problems can occur when your facility is shut down. You must have someone who can respond to all issues during the holidays so you can avoid costly repairs.

We can help! If you’re in South Carolina, eastern Michigan, or western Ohio, our team can check in for you or provide emergency repairs … even during a holiday (Christmas, Thanksgiving, the Superbowl, you name it).

What you need to know about powder coating

Written by Christopher Richmann on September 22, 2023. Posted in Automotive, Coating & Finish Systems, Coating & Finish Systems, Coating & finishing systems, Coating application equipment, Featured, Manufacturing, Woodworking. Leave a Comment

Powder coating, which uses color pigments that start in a powdery state, is an effective way to create a high-quality finish on a variety of products. But you may be asking yourself: Is it right for my operation? You may also be wondering what equipment you’ll need before starting.

Why powder coating?

First, let’s address why you may want to powder coat. Powder systems can create an attractive, durable coating on a wide range of surfaces. It creates an excellent look and feel to the final product, while also leaving a durable finish with cost-effective efficiency.

There are many advantages of powder coating.

Longevity. Powder coating has a strong paint layer, so a coat will last longer compared to liquid paint. In other words, it takes longer for the coating to break down.
More environmentally friendly. Available in a wide range of shades and surface structures, powder coating uses fewer solvents. Because it’s nearly 100% of the powder paint (thanks to the electrostatic system), that also means minimal waste.
Can be less expensive. There is a low expense for safety engineering, a short training period for using powder booths, and an easy adjustment from one color to another. And again, because it’s powder, it may be cheaper than liquid paint.
Versatile. Although powder coating is typically used on metal many objects can use this process, including wood and plastics. The water in the wood acts as the electrical conductor. As long as it can draw an electrical charge and withstand the curing temperatures, it’s a candidate for powder coating. Plastics can be powder coated, but they need a surface finish that can be charged and must withstand high curing temperatures.

Industrial powder coating: the steps and equipment

When considering powder coating systems for your operation, it’s important to understand the process, which is usually divided into three steps: 1) pretreatment of the item, 2) application of the powder, and 3) drying, also known as curing.

Powder coating equipment

You’ll need a powder spray gun or powder booth as well as an oven (for that curing process). Whether you use a spray gun or industrial paint booth, is up to you and the process. There are people who can make recommendations, including Elevated! Contact us so we can help you determine the right equipment, and brands, for your job.

Pretreat the workpiece

The first step in the process is pretreatment, which ensures the surface of the item is ready for the powder. The surface must be clean and free of grease. In some cases, sandblasting or cleaning with special chemicals is required. If the part needs high corrosion resistance, a basic wet chemical can be applied before the powder is added.

Apply the powder

Now that the piece has been cleaned and prepared, the powder can be applied. During this step, the powder will be ejected from the spray equipment to the item. However, the powder will be electrically charged so it sticks to the piece. (Only electrically-conducive items, usually metals, can be powder coated.) While applying the powder, the item will be electrically grounded and the powder electrically charged. This creates an attraction between the item and the powder paint.

There are various processes for charging the item and, depending on the system, the charge may need to be adjusted to create thicker or thinner layers of paint. The charge may need to be adjusted because of temperature, humidity, desire for gloss, or to create abrasion resistance.

Dry or cure the workpiece

After the coat is applied, the workpiece will go through a drying process, which is often referred to as “curing” because the piece is heated, melting the powder so it holds firm.

After the coating is applied, it’s still in powder form. This powder is essentially a composite of plastic and color pigments, that usually cure between 320 and 400 degrees Fahrenheit. The powder contains hardeners that allow the paint to melt, dry, and become a hard coating, all while maintaining an excellent finish.

Is powder coating right for you?

Powder coating can be used on a wide variety of projects from cars and specialty vehicles to furniture. It can be less expensive and greener than using liquid coating plus the quality is durable. Picking the right equipment, whether you’re spraying or using automated spray booths, though can make all the difference.

Elevated can recommend processes and equipment as well as help you make a decision about spraying powder or liquid paint.

Transair piping

Written by Christopher Richmann on June 20, 2023. Posted in Compressed Air, Compressed Air, Compressed Air, Compressed Air, Compressed air systems, Featured. Leave a Comment

If you are installing, modifying, or upgrading a compressed air system, you may consider a variety of different materials for your piping. Options include black pipe, galvanized steel, copper, and stainless steel.

Before making a decision, consider the benefits and drawbacks of aluminum piping. Strong, versatile, and reliable, aluminum piping can bring a fast installation for compressed air systems and better long-term performance for your total operations.

It’s not always the right choice, but for many facilities, aluminum piping is a great option. SmartPipe (by Kaeser) is always a fantastic option. Kaeser is known for their quality engineering. But if SmartPipe isn’t available, we recommend Transair Aluminum Pipe.

Advantages of Transair

Like SmartPipe, it’s easy to connect and modify, making expansions for your compressed air system and facility faster and less expensive. The Transair push-to-connect system creates a firm hold to make the pipes leak-free. It connects with other piping, too. Plus, Transair comes in a variety of sizes, available in 1/2″ to 8″, and includes a warranty.

Unlike SmartPipe, Transair is readily available and may cost less than SmartPipe. (Contact us for details.)

Advantages of aluminum pipes

Aluminum piping brings a variety of advantages that make it ideal for numerous situations. When you need an affordable, durable, long-lasting system that can deliver reliable air compression, aluminum is often the ideal solution.

Aluminum is lighter than most metals. The mounting requirements and time to install are less than other heavier materials.

Aluminum in general is less prone to corrosion, even compared to stainless steel. Even if there is a moisture trap (which we regularly install on air systems) there will be some water in the system, creating the right conditions for corrosion. This is less of a concern with aluminum.

Disadvantages of aluminum piping for air systems

Although it remains one of the best choices for air systems, this pliable metal does have a few disadvantages. The upfront costs may be higher compared to other metals, which may cause some facilities to choose a different material. (But do your research; aluminum can bring long-term savings when installed correctly.)

There can also be more thermal expansion and contraction, so controlling facility temperatures is critical. Although it meets the needs of most facilities, the pressure rating for some aluminum products may be lower as well.

Your source for high-quality aluminum piping

Transair is a leader in the air-pipe industry. The company has a vast collection of lightweight, strong, corrosion-resistant pipes that come in a variety of sizes. These products bring excellent longevity and typically require less maintenance on compressed air systems.

When choosing your piping, you may need the guidance of an experienced professional to ensure the right pipes for your facility. There are a variety of sizes. (You should get the right size for your compressed air system.) Our installation team can help you determine the best options, add drop points, and more. We make it easy from beginning to end (including start-up).

Contact Elevated Industrial Solutions for expert service on your next installation for compressed air systems. We proudly serve western Ohio, eastern Michigan, and South Carolina. We’ll help you select the right pipes for your specific air requirements, and we’ll be available for installation and long-term maintenance.