Compressed Air/Compressors

For decades, leading packagers and industrial users have insisted upon AERZEN compressor stages and packaged units. Why? Because with their exceptional versatility these machines are the ideal solution for every application. Originally designed for compressing air, nitrogen and neutral gases, these all-round geniuses are also developing their strengths in use with special gases, in vacuum operation and in inlet pressure applications. Direct and belt-driven, dry running and classified oil-free to class 0 or with oil injection, with or without pre-inlet. Let’s put it this way: AERZEN has the right compressor for every application.

Screw compressors are perforce twin-shaft rotating lobe machines. They work on the positive displacement principle with internal compression and are so-called compulsive conveyors. This applies for all screw compressors. However, what makes AERZEN screw compressors special is that we have made reliability, ease of maintenance, user-friendliness, flexibility and energy efficiency a matter of principle. The result is a range of unique design features.

Compared to standard compressors they save a considerable amount of energy. And what is the ultimate in compressor technology? It is AERZEN's new E-compressors. With an increase in efficiency of around 6% they free up even more valuable potential.”

The new Contain-Air solution from FPS Air Compressors will transform the way companies gain quick and economic access to compressed air systems. As a turnkey product, the ground-breaking Contain‑Air portable compressed air room arrives on-site pre-installed and ready to use, providing unparalleled convenience, cost reductions and space savings to boost the competitiveness of UK businesses.

Adopting Contain-Air avoids the complex installation, high costs and considerable space demands associated with conventional compressed air systems. This exciting innovation overcomes these challenges by delivering a complete solution that streamlines the entire installation and commissioning process.

By integrating all components into one compact unit, the new containerised solution reduces the need for on-site assembly and minimises the risk of errors. Factories, food plants, hospitals and scientific research facilities - or any other site with a requirement for compressed air - can begin using Contain-Air immediately upon delivery thanks to connect-and-go functionality. This quiet and efficient system requires only power and connection to the air network to get started, ensuring seamless integration into existing infrastructure. Businesses can instead focus on core operations without the hassle of complex set-up procedures, knowing that they are compliant and efficient.

The complete compressed air station includes all the air treatment necessary to meet the demands of any air quality standard: industrial, food production, medical, scientific instrument, breathing air and more. As well as new installations, the system will suit companies experiencing a compressed air bottleneck or unexpected compressor downtime. The convenient Contain-Air ensures users can take advantage of resource-conserving production, process reliability and quality – in double-quick time.

Available in oil-free and lubricated formats, this compressed air cube offers working pressure of 6 to 400 bar, capacity from 1500 to 20,000 l/min and installed power from 11 to 160 kW. Notably, the compact dimensions of Contain-Air minimise the physical footprint required, which is particularly advantageous for businesses with limited space. Firms can optimise their facility layout without compromising any essential equipment.

Each self-contained unit features lighting, excellent service access, heating and ventilation. These weather-proof and extremely durable units also provide maximum security and safety for site personnel.

As a market leader in compressed air solutions, FPS Air Compressors offers innovative solutions that address evolving industry requirements. Contain-Air mirrors this commitment, delivering a product that fuses advanced technology with practicality to set a new benchmark in compressed air system convenience.

For detailed information on the new Contain-Air solution please visit:

www.fps-compressors.co.uk/contain-air

Are the compressed air leaks a problem? How much do industrial gas leaks matter? How long until worn bearings fail?

Lets explore these subjects in more detail, one at a time:-

Compressors are often situated at one end of a factory, connected to the equipment they power via pipework that typically runs through troughs or gantries, out of harms way. It is common to see multiple connections and many tee-pieces along a compressed air installation connecting pneumatic machinery and air tools along the length of a factory. It is rare for the majority of the compressed air circuit to be inspected unless there is a significant issue which is causing disruption to the production process. Afterall, if its not broke, then there is no need to fix it, right?

Similarly for industrial gasses, which are typically installed and refilled in fixed locations close to where the gas is used. These industrial gasses are connected into the production process by protected pipework that is generally ignored after the initial installation unless a significant fault arises.

While it is possible to monitor bearing health using a variety of techniques, the vast majority of bearings are ignored, especially if they are situated in difficult to access locations for example, at height, above machinery requiring production to stop in order to safely inspect their condition.

These three examples are all situations where acoustic imaging can play a role in better informing business about their equipment, both from an Energy Saving and a Preventative Maintenance perspective.

FLIR have launched the Si2 acoustic imaging camera which is able to hear the faults associated with the equipment mentioned, even within noisy operating factories when compressed air leaks, gas leaks or bearing faults are drowned out by the noise of louder production machinery.

Leaks are automatically identified and superimposed onto the 5” LCD colour screen, along with additional information such as the severity of a leak, the predicted cost to a business, or in the case of bearings, the severity of the developing bearing fault. All of this information can be reviewed on-camera, in cloud-based software, or in FLIR Thermal Studio reporting software.

So what? Air leaks are responsible for £1.4 Bn of wasted electricity consumption in the UK alone, repairing these leaks instantly lowers electricity usage associated with compressors and pumps, regaining lost margin for your production process and business profitability.

Gas leaks can be dangerous depending on the gas, but are always significantly more expensive due to the cost to purchase gasses compared to the cost of running air compressors. Repairing these leaks instantly improves the sustainability of a factory and certainly impacts the profitability immediately.

Bearings can be monitored with regular inspections, allowing replacement maintenance work to be scheduled when convenient during periodic shut-down, or addressed more urgently if needed. Most importantly, these insights into bearing condition allows the panned replacement rather than the alternative, which is responding to unexpected failures.

Two of the worst feelings are the panic when a production line stops unexpectedly, and the feeling of losing money. The FLIR Si2 is designed to alleviate both of these feelings by effortlessly identifying leaks that wate electricity and drain profits from a business, and helping to predict maintenance schedules, avoiding downtime.

FLIR offer consultations and in-person demos, with no obligation, to demonstrate the Si2 acoustic camera, allowing you to see first-hand how easy it can be to improve your manufacturing or production operation.

www.flir.co.uk

As of 2024, the entire popular and high-performing Tundra range of refrigerant air dryers from Hi-line Industries will transition to R-513A, a refrigerant with zero ozone depleting potential (ODP) that helps customers to enhance their sustainability credentials. Although Hi-line attributes the success of the Tundra range in compressed air applications to its ultra-reliable performance, energy efficiency and reasonable price tag, the introduction of R513-A and its zero ODP means there really is no need to go anywhere else for refrigerant air dryers.

R-513A (Opteon™ XP10) refrigerant is a hydrofluoroolefin (HFO) based replacement for R-134a. Ideal for use in medium and low temperature refrigeration products, such as Tundra air dryers, R-513A offers 56% lower GWP (global warming potential) than R-134a, delivering long-term sustainability and F gas legislation compliance.

Notably, R-513A resides in the A1 (non-flammable) safety class, making it an ideal retrofit candidate for R-134a, while offering very similar cooling performance. R-513A also provides negligible temperature glide to ensure reliable performance day after day.

Despite the new innovation in refrigerant development, Hi-line intends to hold pricing for the Tundra range firm throughout 2024. This initiative will help customers combat challenging trading conditions and remain competitive in their respective industries.

Tundra refrigeration air dryers are in widespread use across UK industry, improving the quality of compressed air, protecting valuable assets, and outperforming rival technologies in energy efficiency by minimising pressure drop and lowering absorbed power. Among further features driving Tundra’s energy-efficient characteristics is a patented single-cell heat exchanger, which delivers highly efficient heat transfer at low energy costs, and a link between the controller and condensate removal valve for minimum loss of compressed air during condensate discharge. To indicate the regard held for Tundra as a value-added solution for companies running compressed air systems, this innovative product recently gained recognition at the prestigious iPlex Awards, in the ‘Energy Management Innovation’ category.

Indeed, the acknowledgement of Hi-line’s impact on industry stretches far beyond Tundra refrigeration air dryers, with Managing Director Steve Smith’s recent induction into the Industrial Plant and Equipment Hall of Fame a case in point. Steve Smith has a depth of experience in the compressed air sector that spans over 40 years. In particular, the judges praised his commitment to corporate social responsibility, whether it is his willingness to take the lead on charity initiatives, or Hi-line’s sponsorship of local sporting teams. On this note, the company will continue to sponsor Tom Hamer, defender at League One football club Burton Albion, throughout the 2023/24 season.

Hi-line are also sponsors of Burton Rugby Football Club – First Team with the logo on the chest of all the First Team Shirts. Along with the sponsorship of the Hi-line Moto X team, this year Hi-line’s sponsorship is extend further by sponsoring Help for Heroes to enable the rehabilitation of war veterans to travel pillion on a motor cycle along Route 66.

Further information is available from: Hi-line Industries Ltd,

Green Street, Burton on Trent, Staffordshire  DE14 3RT

Telephone: 01283 533377                                           Fax: 01283 533367              

e-mail: This email address is being protected from spambots. You need JavaScript enabled to view it.                      www.hilineindustries.com

The British Compressed Air Society (BCAS) has appointed Steven Rohan as its new president.

Steven is the division engineering manager for Parker Gas Separation and Filtration Division - Europe, Middle East and Africa and takes over the role from immediate past president, Mark Ranger from Atlas CopCo.

Having held the role of vice president for the past two years, Steven is keen to build upon the excellent foundations set by the Society's predecessors and to ensure that BCAS continues to play its crucial role in driving progress in the compressed air industry.

Said Steven:

"It is an honour to be appointed as the 59th president of BCAS, a society that has been at the forefront of promoting safety and best practice in the compressed air industry for more than 90 years.

"The world is changing rapidly. We are facing new challenges from the increasing demand for energy efficiency and more cleaner and sustainable technologies. With this comes changing legislation and standards in a post-Brexit regulatory landscape and, BCAS has a key part to play in representing its broad membership and as an independent voice of the compressed air industry.

"To add further value for our membership, during my tenure I will also focus on talent acquisition and development. Our training and development portfolio and qualification programs will be broadened and strengthened, forming closer partnerships with the education sector. This will support the aim to attract more talent to our industry and our members' businesses."

As part of the Society's ongoing plans to boost growth, the BCAS team will be strengthened further too.  Vanda Jones will continue in post, providing governance and stability while a new executive director is appointed, before continuing in the new role as company secretary. 

Tim Preece, as technical officer continues to expand the Society's remit in the areas of EU and global standards and legislation, and a new training and development officer will be announced shortly.  Frances Marsh also continues in her vital role as society administrator, providing membership support to manufacturer, distributor and end-user members.

Commenting on Steven’s appointment, Vanda Jones, BCAS Executive Director added:

“At board level we now have a wealth of experience across the team, with a balance of manufacturer and distribution directors to better represent our membership.  This ensures we continue to support all our stakeholders on the issues that matter most to their businesses - whether it's lobbying for changes in legislation to deliver a better outcome for customers, providing guidance on energy reduction or delivering technical training. 

“It is an exciting time for Steven to be leading the BCAS board and I look forward to working with him to support all our members and compressed air end users.”

For further information about the British Compressed Air Society, please visit www.bcas.org.uk

SICK has launched an Industry 4.0 on-premise data intelligence platform that empowers manufacturing and logistics organisations to optimise their operating performance. SICK Field Analytics can be quickly and easily set up to provide meaningful, application-specific condition monitoring and process insights, independently of an organisation’s existing machinery and systems.

SICK Field Analytics is a vendor-agnostic digitalisation platform that collects and aggregates data from any source, including sensors, machine controllers and other IIoT devices. The software can be configured to display real-time data, to provide timely alerts and alarms, and to visualise historical trends through powerful dashboard graphics.

Data Insights for Improved Performance

Using the SICK Field Analytics software solution and a dedicated computer, users can aggregate data from disparate machines and automation systems or augment legacy automation systems to provide additional data insights. The solution is highly scalable, enabling users to adopt it on a project-by-project basis or at a wider organisational level.

Charlie Walker, SICK UK’s Digital Solutions Consultant, says the SICK Field Analytics platform can support users to progress towards greater Industry 4.0 digital maturity:

“Operators who want to gain more insights across a production floor, factory or warehouse may feel quite daunted by the prospect of collecting and comparing data from many different machines or applications.

“Faced with a sea of information, it can be difficult to isolate the specific factors that are affecting operating efficiency. The data could come from all sorts of sources that use different communications protocols. Information could even still be recorded manually, be stuck in silos, or bogged down in bottlenecks.

“Even if operators already extract some data from their existing automation, they can find themselves locked out of PLCs or other systems, such as “legal for trade”. So, they cannot increase the amount of diagnostic data from their legacy systems, even when they replace switched devices with IO-Link sensors, or configure edge integrations using IO-Link Masters.”

Interrogate Operating Efficiency

“Field Analytics can solve these problems easily by collecting data from all these disparate sources without costly and time-consuming adaptation of existing systems. Operators can extract more information about the health of their machines, while interrogating their operating efficiency in new, and sometimes surprising, ways.”

The SICK Field Analytics software platform can be used in combination with data extracted from a wide variety of existing sources, including sensors from any vendor, PLCS, and smart IIoT edge devices such as Sensor Integration Machines. Where necessary, SICK can work with a customer to add smart sensors and edge devices to machinery or automated systems as part of a dedicated Field Analytics project.

Powerful Dashboards and Alerts

SICK Field Analytics incorporates a user management module to manage access rights. The data collected will depend on each organisation, but could range from the service status of sensors through to key data about the health of machinery, such as vibration, temperature, or shock. Organisations can configure their Field Analytics package to better understand the condition of their machinery using powerful dashboard graphics and visual alerts.  

Operators can set up and trend Key Performance Indicators both historically and in real time. Through real-time alerts, they can react more quickly to production or process anomalies that might otherwise lead to machine downtime.

Field Analytics can track overall operating effectiveness. The dashboard features can be also trend other measurements important to an organisation’s profitability and efficiency. For example, it could monitor compressed air usage or calculate and track production costs, for example of energy consumption.

SICK Field Analytics can also enhance the data already available from legacy automated systems, including those that operate at a higher organisational level. SICK Field Analytics is compatible with most common communications protocols, including Rest API, OPC UA and MQTT. 

www.sick.co.uk

Regardless of whether the business is an automotive workshop, a small-to-medium sized manufacturing company or indeed any type of operation that simply needs dry and clean compressed air, the new G-TEC Air Compressor from FPS provides a complete compressed air workstation with ‘game-changing’ capabilities. This 6-in-1 offer comprises a high-performance compressor, refrigerated dryer, dual filtration, 270/500 litre air receiver, oil-water separator and controller, making the G-TEC Air Compressor the optimal and most convenient choice, for a whole host of applications.

Avoiding the need for many individual components that typically form part of a complex compressed air system, the G-TEC workstation features an integrated and modular design that saves space, reduces installation and improves efficiency. It delivers outstanding performance, producing a consistent supply of compressed air to power a wide range of pneumatic tools and machinery. With its high-efficiency motor and innovative design, this complete workstation also meets the growing demand for more sustainable and cost-effective compressed air solutions.

G-TEC workstations from FPS are available with a range of 7.5 to 22kW with pressure from 8 to13 bar. The high-efficiency screw compressors ensure optimal productivity and reliability. Importantly, the workstation comes with a 270 or 500 litre receiver and an integrated dryer and filters. The result? Clean, dry air for quality-assured pneumatic operations that lead to reduced downtime and maintenance costs and Indeed, reduced corrosion within pipes that also means fewer product rejects, and fewer costly air leaks, delivering yet more savings.

Another integral component of the G-TEC Air Compressor workstation is the condensate oil-water separator, supplied as standard by FPS to reduce environmental pollution. Furthermore, the intuitive built-in control panel makes using the G-TEC workstation easy to use for operators of all skill levels.

Among the business that can take advantage are automotive workshops. From tyre centres to body repair shops, the task of paint spraying and when using general garage equipment can benefit from the fixed and variable-speed models of G-TEC Air Compressor line-up. As a particular point of note, noise output is exceptionally low.

Further applications include pneumatic tools on production/assembly lines, woodworking tools such as sanders and staplers, and plasma/laser cutting. In all cases the outcome is the same: high-quality, professional compressed air delivery with economy and sustainability in mind. When operating variable-speed models, the remarkable energy-saving capabilities of the G-TEC Air Compressor workstation render it an environmentally responsible choice that also reduces operational costs by as much as 30%.

With its fully integrated components, the compact design of the G-TEC Air Compressor makes it ideal for any customer where space is at a premium. This, when combined with straightforward installation and maintenance, allows the G-TEC workstation user the benefit of a hassle-free and highly cost-effective solution for businesses of all sizes.

“Users of the G-TEC Air Compressor can achieve the perfect balance between power and efficiency, ensuring that your compressed air needs are met without excessive energy wastage,” states Moiz Palaci, Director of FPS Air Compressors. “At FPS, we are committed to providing innovative solutions that meet the evolving needs of customers. Our G-TEC Air Compressor is no exception, boasting a range of features that make it the ideal choice whenever low noise, energy efficiency, convenience and reliability are primary demands.”

Purchase, lease and rental options are available.

For detailed information on the G-TEC range of air compressors please visit:

www.fps-compressors.co.uk/gtec.html

Convey parts, materials, waste - with no moving parts!

 A Line Vac Air Operated Conveyor is a fast, low cost way to convey plastic pellets, scrap trim, bulk solids, food products, and much more.

EXAIR’s compressed air operated Line Vac connects to standard hose or tube to create a powerful in-line conveyor. The compact design features large throat diameters for maximum throughput capability. Eleven sizes in aluminum and ten in stainless steel are suited to a wide variety of transfer applications.

Line Vac conveyors are ideal for moving large volumes of material over long distances. A small amount of compressed air is injected through directed nozzles to produce a vacuum on one end and high output flows on the other, with instantaneous response.

Threaded Line Vacs, Heavy Duty Line Vacs, Heavy Duty Threaded Line Vacs, Sanitary Flange Line Vacs and Light Duty Line Vacs are also available in stock at EXAIR. Learn More and watch our helpful videos.  https://exair.co/190_564

By releasing the new MGF X Line range of oil-free compressors into the UK market, FPS Air Compressors is providing dental labs running CAD/CAM-driven milling machines and 3D printers with a proven way to utilise a continuous and highly reliable source of clean, dry compressed air without risk of contamination.

Computer-Aided Design/Computer-Aided Manufacturing (CAD/CAM) systems are finding growing use in the creation of dental restorations such as crowns, bridges and veneers. The new X Line can supply clean and dry compressed air continuously and reliably to CAD/CAM-driven milling processes, ensuring the precise, reliable and high-integrity production of dental prosthetics.

A further benefit of using innovative MGF X Line compressor technology at dental labs is increased air capacity and, subsequently, lower energy bills. This advantage arrives courtesy of a patented MGF system that reduces the air requirements of the membrane dryer, which in turn increases the available flow of air from the compressor by 20-25% to help optimise dental lab processes such as milling.

The X Line is also ideal for serving 3D printers, which although an additive rather than a subtractive process like milling, still need a compressor that provides continuous, high air quality and low vibration to support the precision and stability demanded by the 3D Printers industry. Notably, as 3D printing technology becomes more widespread, the importance of air quality in the printing process is gaining more and more attention in the process.

                                                                                                                                                                        Continued ……

Producing consistent air quality is a primary capability of X Line compressors, which house a 0.01 µm filtration system and a high-quality, high-efficiency membrane dryer. The provision of clean, dry, continuous air allows dental labs everywhere to take advantage of uninterrupted workflows. X Line compressors run at a maximum pressure of 10 bar, producing constant air flow at the capacity stated from a broad range of models suitable for multi applications.

Offering yet another advantage, the low vibration of the cabinet-housed X Line air compressors contributes to quiet operation. In addition to the four ‘Base’ models, a trio of ‘Silent’ versions are available providing low noise levels that do not exceed 53-56 dB(A). Furthermore, with the robust build quality, X Line compressors offer highly durable operation and a long service life, helping to minimise total cost of ownership (TCO) for dental labs.

Ultimately, the MGF X Line combines efficiency, performance and reliability with extremely quiet operation, providing genuine added value to dental labs running CAD/CAM-driven milling and 3D printing processes.

In addition, FPS extensive range of oil-free and SCROLL compressors are suitable for a myriad of applications in other sectors that demand high air quality. These include: product handling and packaging at food and beverage plants; aseptic processes and cleanrooms in pharmaceutical facilities; circuit board manufacturing and chip production in the electronics market; jet looms and air splicing at textile factories; testing and analytical instruments at research laboratories; and sampling and analysis devices in environmental monitoring processes.

For further information on the X Line range oil-free compressors please visit:
https://www.fps-compressors.co.uk/oil_free_compressors-cadcam_applications.html

Compressed air and fluid power specialist Thorite have added hydraulic power pack maintenance and repairs to their vast portfolio of service solutions. This comes as a response to the demands of the numerous Energy from Waste sites choosing Thorite as their trusted service partner.

The company’s dedicated Energy Recovery Facility (ERF) Team will exhibit at the Resource and Waste Management (RWM) Expo at the Birmingham NEC from 13^th -14^th September where they will showcase a range of products and services designed to help ERF and EfW sites to improve efficiency, reduce energy consumption and achieve cost savings.

These include:

• The new comprehensive hydraulics service, which includes hydraulic power pack and hydraulic cylinder overhaul, repairs and post inspection reporting.

• A display of Norgren and SMC impact rapping cylinders, which are ideally suited to the removal of slag in ERF / EfW conversion facilities, optimising pneumatic power to deliver improved reliability and low maintenance costs.

• Next generation Gardner Denver compressors, with unparalleled efficiency and featuring ICON monitoring software to support predictive maintenance programmes.

• Energy saving services such as leak detection surveys and energy audits.

• Air and fluid power support, from install and start up to workshop overhaul.

Thorite’s ERF Team Manager, Josh Davis, said: “Our new hydraulic repair service is a unique offering and is a valuable addition to our range of bespoke services and products developed specifically for energy recovery sites.

This is Thorite’s first visit to the RWM Expo and we’re looking forward to sharing our expertise, built on more than a century of experience in hydraulics and pneumatics, at the UK’s leading event for the sector.”

Visit Thoite at stand stand R-K251 at the RWM Expo on 13^th & 14^th September at the NEC

or contact the ERF team on This email address is being protected from spambots. You need JavaScript enabled to view it.

This article can also be found in the issue below.