Compressed Air/Compressors

To coincide with this year's National Apprenticeship Week, the British Compressed Air Society (BCAS) has launched a new apprenticeship pack, to guide employers, apprentices and their parents throughout the process.

Included in the pack is a new best practice guide for employers, to support the recruitment, management, and development of apprentices in the compressed air and vacuum industry.

The guide offers comprehensive advice on apprenticeship structures, recruitment strategies, mentoring, and legal obligations, helping businesses attract and nurture new talent. It highlights the importance of paid apprenticeships, structured induction processes, and safeguarding measures, ensuring apprentices receive the best possible start to their careers.

In addition, a handy guide for apprentices explains the areas to consider when choosing an apprenticeship and what to expect during studies. Plus, there is a step-by-step overview for parents and guardians that are keen to support their child to get the best out of their new career.

BCAS, alongside its members and the Institute for Apprenticeships and Education (IfATE), was instrumental in the development of a dedicated compressed air and vacuum industry apprenticeship, an industry first. 

The industry-specific pathway has already helped the next generation of skilled professionals, providing standardisation of their skills, competence, behaviours and safe working. The standard ensures that upon successful completion, the apprentice achieves a national apprenticeship, academic qualifications and may apply for the professional recognition of EngTech with The Society of Operations Engineers.

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However, as Terry Collier, Learning and Development Officer at BCAS explains, many businesses, especially those new to recruiting apprentices are keen to receive extra support.  He said:

"Many of our BCAS members are smaller SMEs that do not have access to large HR departments to assist with recruitment and training.  At the same time, these members have a highly skilled workforce made up of professional engineers that have a vast amount of knowledge and experience.  There is a real desire to pass this expertise onto the next generation, especially to help address the continuing engineering skills gap.

"Our new apprenticeship pack has been launched to help our members, and the wider compressed air engineering community achieve precisely this.  A key focus is on workplace integration, with guidance on creating a structured work plan, assigning meaningful tasks, and providing effective mentorship.

'In addition, our accompanying apprentice and parents' guides provide practical, friendly advice during this key stage in a young person's career."

The guide also outlines the recent government funding changes, including full funding for small and medium enterprises (SMEs) and increased flexibility in Apprenticeship Levy transfers.

BCAS members can download this pack. Please click here

Fay Hutchinson has joined the British Compressed Air Society (BCAS) in the newly created role of Learning Support Officer.

Working alongside Terry Collier, BCAS’s Learning and Development Officer, the new role will see BCAS further enhance the breadth and range of compressed air and vacuum training courses and approved accreditations available, with particular focus on increasing participation in its compressed air and vacuum technician (CAVT) apprenticeship.

Fay has a wealth of training experience, gained in roles both within engineering and the higher education sector. Starting her career in the stainless steel and aluminium sector, Fay holds a first-class honours degree in business management and a master of business administration (MBA) and has recently completed a level 6 diploma in career guidance and development.

Of particular benefit to BCAS and its members is Fay’s experience gained during her work with higher education institutes.  She has held several employer relationship roles, most recently at the University of Greenwich, where she has secured successful industrial work placements for students during their university studies.  She has also been actively involved in encouraging businesses to offer degree apprenticeships, using their apprenticeship levy where appropriate to either bring new talent into the business or to upskill existing members of staff.

Commenting on the appointment, Ashley Quarterman, BCAS Executive Director said:

“The industry is only too aware that recruiting and retaining skilled staff into the compressed air and wider engineering sector is challenging.  Offering high-quality training, whether through our apprenticeship scheme or one of our many CPD-approved courses, can help to deliver the next generation of engineers that our sector needs.

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“It is great to welcome Fay to the team and to be able to draw on all her experience in both the industrial and education sectors.  She understands how effective learning environments can be created, alongside the pressures faced by employers to continually train their teams and this will be of genuine benefit to our members.”

Fay added:

“I am really looking forward to using my skills to help further enhance the training support available to our members.  I am already speaking to members about our CAVT apprenticeship and some of the ways we can refine it further through progression routes, as well as being able to advise on the range of bursaries and levy funding that could be available.”

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

Birmingham-based Armac Martin, a pioneer in design-led luxury brass hardware and accessories, relies heavily on compressed air for its CNC machining requirements. However, the company’s existing system was constantly operating at full capacity, leading to unnecessary energy expenditure. By collaborating with FPS Compressors and its preferred local distributor Compressed Air Systems UK - Birmingham, Armac Martin adopted a new system capable of variable compressed air supply. The project led to an impressive 46% reduction in energy consumption compared with the company’s previous compressor.

Founded in 1929 as a local brass foundry, Armac Martin is today a fourth-generation family business with a global reputation for exceptional design and craftsmanship. Compressed air is critical to the successful operation of the company’s modern CNC machining centres. At the same time, like all manufacturers, Armac Martin is driving to make its operations more sustainable. The company has a strategy to achieve net zero by 2041, making the significant energy drain of its compressed air system a cause of major concern.

Collaborating with FPS Compressors and Compressed Air Systems UK - Birmingham, Armac Martin opted for a new system capable of variable compressed air supply, identified through data logging and energy audit exercises. Monitoring of the system took place using state-of-the-art instruments over several weeks. FPS Compressors and Compressed Air Systems UK - Birmingham explained both the data and the recommend solution to Armac Martin’s management team. Notably, the transition to the new compressed air system, which features a NOBEL 18.508 DVF PM variable-speed screw air compressor from FPS at its core, was seamless and without downtime. Comprehensive training ensured proficiency in operation.

With the NOBEL 18.508 DV FPM, compressed air aligns to system requirements by regulating the speed of the electric IE4 permanent magnet motor, which can range from 15-100% of the maximum speed. Notably, the direct-drive system means zero energy losses, whereas standard drive belts may incur losses of 4-11% as the energy transfers from the motor to the compressor. Excellent and precise pressure control extends from 6 to 13 bar, while accurate and optimised cooling of the compressor arrives courtesy of efficient, powerful and quiet radial fans.

By partnering with industry experts and embracing innovative technologies, Armac Martin is seeing a remarkable 46% reduction in compressor energy consumption, translating to an impressive £23,637 in annual savings. The return-on-investment [ROI] for this sustainable initiative was achieved in just 14 months.

“The use of compressed air represents a large chunk of electricity costs at machine shops such as Armac Martin, just like it does at any manufacturing plant, food production facility or packaging plant,” says Nick Poole, Managing Director at FPS Air Compressors. “To make gains, users of compressed air must get smart about specifying the optimal technology, notably the compressor. Armac Martin is a great example of what this strategy can deliver. While the company’s previous compressed air system ran constantly at full capacity, the new solution reduces power requirements by only meeting actual demand. The result? Significant improvements in energy efficiency without any compromise in manufacturing performance.”

For additional information on this case study please visit:
www.fps-compressors.co.uk/fps-case-study-armac-martin.html

Further information is available from:

FPS Air Compressors Ltd, Unit 5, Tower Estate, Warpsgrove Lane, Chalgrove Oxfordshire OX44 7XZ

Telephone: 01865 892 620                                          e-mail: This email address is being protected from spambots. You need JavaScript enabled to view it.

www.fps-compressors.co.uk

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