Compressed Air/Compressors

 Stop electronic control downtime due to heat, dirt, and moisture!

Cabinet Coolers maintain NEMA 4, 4X, and 12 integrity. All Cabinet Coolers are UL Listed and CE compliant!

A low cost, reliable way to cool and purge electronic control panels. EXAIR Cabinet Coolers incorporate a vortex tube to produce cold air from compressed air - with no moving parts. The compact Cabinet Cooler can be installed in minutes through a standard electrical knockout. NEMA 12, 4, and 4X Cabinet Coolers that match the NEMA rating of the enclosure are available in many cooling capacities for large and small control panels.

The vortex tubes incorporated in the EXAIR Cabinet Coolers are constructed of stainless steel. The wear, corrosion and oxidation resistance of stainless steel assures long life and maintenance free operation. Check out our Hazardous Location Cabinet Coolers for use with classified enclosure purge and pressurization systems. https://exair.co/190_540

Delta Hybrid represents one of the most groundbreaking advancements in compressor technology and stands out as an exceptionally efficient system within its class. These latest models are equipped with intelligent features, enhanced functionality, and remarkable energy savings of up to 30% when compared to traditional positive displacement blowers.

AERZEN rotary lobe compressors, or screw blowers combine the benefits of blower and compressor technology into a single, versatile system, catering to a wide range of performance requirements for various industrial processes. These assemblies are primarily designed for oil-free air conveyance and serve an extensive array of key industrial applications, including pneumatic conveying, homogenisation, and wastewater treatment. The newly introduced models deliver energy efficiency, feature a simplified service and maintenance concept, and smaller footprint, which contributes to minimising the Total Cost of Ownership (TCO).

Thanks to an innovative compressor stage equipped with highly efficient screw profiles, internal flow optimisation, standard motors with energy efficiency class IE4, optimised process and cooling air flow, and a self-tensioning belt drive is over 98% efficiency in conjunction with a compact design, substantial energy savings of up to 30% can be achieved compared to traditional blowers. The patented bearing ensures a service life 70,000+ hours. An effective sealing mechanism for the driving shaft and conveying chamber minimises natural wear, guaranteeing oil-free operation in accordance with ISO 8573-1 class 0 standards. Additionally, the patented reactive silencer, free from absorption materials, effectively prevents process air contamination and safeguards downstream systems, making it particularly advantageous for sustainable, safe, and long-lasting operations in the food industry and wastewater treatment. The intelligent oil system, which functions with minimal oil quantities and extended change intervals of 16,000 operating hours, positively impacts longevity and maintenance.

www.aerzen.com

This article can also be found in issue below.

A campaign which shone a light on the high cost of wasted energy in compressed air systems has put Thorite in the running for two major awards.

The compressed air and fluid power specialist created the ‘Behind Closed Doors’ campaign to raise awareness in the manufacturing sector about unseen compressed air inefficiencies which lead to high energy bills and have a negative environmental impact.

The campaign has now been shortlisted for Best Marketing Campaign in the national Instrumentation Excellence Awards and for the Creative for Good Award in the Prolific North Creative Awards.

Thorite’s Marketing Manager, Carl Davenport said: “We're very proud that our small in-house team has been recognised amongst some of the biggest and best creative agencies in the country.

“Our aim with the campaign was not only to highlight the financial and environmental impact that wasted energy has on UK manufacturing when it goes unmonitored, but also to provide energy saving solutions to manufacturers who need to rein in costs during this tough economic climate.

“The response to the campaign has been incredible and we’re delighted that ‘Behind Closed Doors’ has been recognised not just by the engineering industry and the environmental & sustainability press, but also by our creative peers.”

The Prolific North Award winners will be announced on June 29^th and the Instrumentation Excellence Award winners on October 19^th.

www.thorite.com

this article can also be found in the issue below.

Manufacturers face a £20,000 fine and, at worst, imprisonment, for failing to comply with regulations which cover the disposal of compressed air condensate. Yet many companies are unaware of the regulations and their responsibilities under it, warns Steve Boults, of compressed air and fluid power specialist Thorite. Here he explains how you can avoid putting both your finances and reputation at risk.

Almost all manufacturing processes use compressed air in their operations and condensate is a by-product of the compression process.

It is caused when the compressed air temperature decreases and turns back into a liquid, which contains contaminants such as lubricants, solid particles and airborne micro-organisms which were present in the compressed air.

Compressed air condensate is classified as hazardous waste and the legislation relating to its disposal is stringent. Companies which fail to comply can face fines of £20,000 and, in worse case scenarios, directors can face a prison sentence.

The solution to safely disposing of condensate – an oil/water separator - is simple and relatively low cost. Yet the number of compressed air users who do not employ one is surprisingly high.

We estimate that as many as 40% of compressed air plants fail to employ an oil/water separator, and a further 5% to 10% have one but fail to maintain it properly. This can apply to SMEs and multinationals alike.

The result is that toxic waste from their processes is draining to the ground and potentially making its way into waterways.

The legal ramifications and environmental implications alone should give companies pause for thought. But additionally, a compressor without an oil/water separator is also a compressor which is very likely to be performing inefficiently, as the build-up of oily condensate will eventually cause damage, leading to downtime and repair costs.

With the penalties for breaching the legislation so high it is essential that both company managers and operatives on the factory floor understand the regulations that govern condensate treatment and the steps they must take to meet them.

Safe disposal of condensate

Companies must handle all condensate and associated materials, from filters to spillage mats, in compliance with the Hazardous Waste (England and Wales) Regulations 2005.

This is as simple as installing an oil/water separator to separate the emulsified oil and waste water. Separators can cost as little as £100 and even at the larger end of the scale will only cost a few thousand pounds. They can also be retrofitted.

With relevant permissions, the waste water can then be drained to the foul sewer, while the oil collected must be removed by a registered Hazardous Waste Producer or Licensed Waste Carrier, usually on an annual basis.

If an oil/water separator is not fitted, this mix of pollutants is discharged into the compressor house drain and eventually makes its way into the nearest waste water system or, worse still, directly onto the compressor house floor where it drains to the ground outside. This activity is illegal.

The cost of failing to comply

If you have a compressed air system producing condensate, you are governed by a further two key pieces of legislation.

Water Resources Act 1991

This states that it is an offence to knowingly permit entry of toxic waste to surface or ground water. The penalty is a fine of £20,000 or more in a Crown Court.

Water Industry Act 1991

This sets out the administrative requirements relating to the discharge of the treated condensate water, such as gaining consent from the local sewerage service provider and provision of analysis data and records if requested.

It also states that under no circumstances can treated condensate water be discharged to open water such as rivers and streams, ground water or storm/rain water drains and that penalties for breaching the Act can result in fines of up to £20,000 and potential imprisonment for company directors.

The solution is straightforward - so why is the number of companies failing to fit an oil/water separator so high?

The main reason appears to be a genuine lack of awareness of the legislation, at all levels.

Management are unfamiliar with the law and consider oversight of the compressor house as belonging to the engineering or maintenance teams, while operatives might have inherited legacy equipment which never had a separator fitted, and have no cause to question the status quo. Therefore, responsibility falls between two stones.

Failing to comply with the regulations around condensate disposal presents a very real cost in terms of equipment efficiency, potential fines and professional reputation, not to mention the ethical implications of polluting the local environment.

Is that risk really worth the price of an oil/water separator?

www.thorite.co.uk

EXAIR's Super Air Knife™ is the latest generation of our engineered air knife. It dramatically reduces compressed air usage and noise when compared to other blowoffs. The Super Air Knife offers a more efficient way to clean, dry or cool parts, webs or conveyors. It delivers a uniform sheet of laminar airflow across the entire length with hard-hitting force.

Advantages

Noisy blowoffs become a whisper when replaced with the compact Super Air Knife. Even at high pressures of 80 PSIG (5.5 BAR), the sound level is surprisingly quiet at 69 dBA for most applications! Air amplification ratios (entrained air to compressed air) of 40:1 are produced. Meets OSHA maximum dead-ended pressure and noise requirements. https://exair.co/190_523

For over 150 years, AERZEN has been developing, manufacturing and supplying rotary lobe blowers and subsequently oil-free and oil-flooded screw compressors for complex and demanding air and gas applications.  Our history has given rise to a unique knowledge of technological advances and know-how.  AERZEN technology and experience gaines in more traditional industries and applications are more and more frequently being applied to emerging industrial applications to meet the sustainable challenges facing all of us.  Built with AERZEN know-how and wealth of experience come compression solutions engineered for Hydrogen applications.

Made by AERZEN, made in Germany.

Aerzen Machines Ltd

Aerzen House, Langston Road, Loughton, Essex, IG10 3SL

T +44 0208 502 8100

E This email address is being protected from spambots. You need JavaScript enabled to view it.

W www.aerzen.com

This article can also be found in the issue below.

This advanced acoustic camera for industrial uses improves performance, efficiency, and ease of use with one-hand operation to pinpoint issues at a safe distance
GOLETA, Calif., April 6, 2023― Teledyne FLIR, part of Teledyne Technologies Incorporated, today announced the Si124–LD Plus, a new addition to its line of Si124 acoustic imaging cameras. This new model provides professional inspectors with an enhanced user interface and software features that improve the ability to pinpoint smaller air compressor leaks more quickly and accurately than ever before to make industrial environments safer and more productive.
The Si124-LD Plus maintains its ergonomic one-hand operational design while offering a number of enhancements to improve its utility and efficiency, including:
AutoFilter: automatically determines the best filter to use for revealing small leaks that might otherwise remain undetected, all the while speeding up inspections by eliminating unrelated background noise.
AutoDistance: automatically measures the distance to the leak for real-time, reliable, leak-rate estimates up to five meters (16 feet) away from the source.
Continuous Auto-Correct:

improves leak detection performance to find even smaller air leaks from 0.016 l/min to 0.004 l/min (0.016 l/min = 0.00057 cfm, 0.004 l/min = 0.00014 cfm).
“The Si124-LD Plus acoustic imaging camera represents a step change for industrial compressed air leak inspection,” said Rob Milner, Director, Global Business Development, Teledyne FLIR. “The Si124 line of acoustic imaging devices has already proved to decrease inspection time 10-fold, and now with additional software features such as AutoDistance and AutoFilter with the ‘plus’ version, industrial inspectors will enjoy even greater efficiency and the ability to detect even smaller leaks than what was once possible. These leaks, if not detected and remedied, can create not only dangerous conditions for buildings and industrial sites but can lead to costly repairs and unnecessary increases in energy costs.”
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The acoustic imaging camera also features an upgraded user interface (UI) and full integration with the powerful FLIR Thermal Studio software for post-inspection analysis and reporting. Importantly, the Si124-LD Plus provides leak quantification both on camera and in software, allowing inspectors to better prioritize repairs and justify expenditures.
FLIR Thermal Studio Integration

FLIR Thermal Studio empowers operators to import acoustic images from the camera to the desktop software suite to easily edit and analyze acoustic imagery alongside multispectral imagery capture from other Teledyne FLIR inspection tools. This enables inspectors to create advanced reports as part of a comprehensive predictive maintenance or condition monitoring program across the visible, thermal, and acoustic spectrums. The software gives users the ability to create reports through pre-built or fully customizable templates, including multispectral image analysis in the same report or even the same page via drag-and-drop report creation functionality.
The Si124-LD Plus includes two rechargeable batteries with a battery recharger, a neck strap, and a USB memory stick included within a hard case for safe, easy transportation to and from the job site.
Visit www.flir.com/Si124-LD-Plus for more information and to book your demo.

Compressed air and fluid power specialist Thorite has made two new appointments to develop its specialist support in electric automation and systems building.

Electrical engineer Aniq Rehman has joined Thorite as a Technical Specialist in electric automation.

After completing a degree in Electrical and Electronics Engineering at Bradford University, Aniq has worked as an electrical design engineer, most recently for  Wakefield-based PCM Automation, where he developed his expertise in designing end of arm tools for six-axis robots.

In his newly created role at Thorite, he will help develop the company’s capabilities in electric automation, carrying out systems building and providing technical support to sales colleagues and customers.

Owen Parry is Thorite’s new Systems Production Engineering Manager.

His multi-faceted role will involve working with the systems team to help achieve Thorite’s plans for growth. He will also assist with business development and provide technical support to colleagues and customers.

As a mechanical engineer, Owen’s varied career has included being a calibration planning engineer for Johnson & Johnson, medical design engineer for Tissuemed and engineering manager for Freudenberg Nonwovens LP. In addition, Owen is a qualified teacher, working most recently at UCT Leeds, a specialist engineering school.

Mike Perry,  Technical Solutions Manager for Thorite, said: “Many companies are moving towards electric automation and we have significantly strengthened our expertise in this area to help customers achieve that shift successfully.

“Systems building is a bedrock of our services and is a key growth area for Thorite.

“We’re delighted to welcome Aniq and Owen to the company to consolidate our capabilities and support our plans for growth.”

With energy bills likely to remain high for some time, users of compressed air must consider every potential energy-reducing measure. In tandem with growing demands to reduce carbon footprint as the UK transitions to a net-zero future, many companies are looking at compressed air technologies for the solution. Air dryers, which are essential to improve the quality of compressed air and protect valuable assets, are no exception. With this thought in mind, Hi-line’s latest Tundra range of refrigeration air dryers is its most energy-efficient to date, helping companies reduce costs, remain competitive and boost their green credentials.

Tundra refrigeration air dryers outperform rival technologies in energy efficiency by minimising pressure drop and lowering absorbed power. The principle of operation is direct expansion, which offers a notable advantage over thermal expansion dryers, namely a far more stable dew point of +1°C at all load levels. This stability contrasts greatly to thermal expansion dryers, where dew points can range from +3°C to +20°C. Importantly, this impressive stability in no way compromises performance: Tundra refrigeration dryers deliver continuous dry air that satisfies ISO 7183 industry standards.

One of the secrets behind the energy-efficient Tundra series is the improved and patented single-cell heat exchanger, which delivers highly efficient heat transfer at low energy costs. In essence, pre-cooled air enters the all-aluminium heat exchanger module while post-heated air departs, supporting a reduction in the energy consumed by the chiller circuit.

Another energy-saving attribute of the Hi-line’s Tundra range of refrigeration air dryers involves condensate removal. A link between the microprocessor controller and the condensate removal valve ensures minimum loss of compressed air during condensate discharge, again saving energy. This function is fully programmable in line with climatic and seasonal conditions.

A variable-speed fan is among further energy-reducing technologies that help to drive down bills. Fan speed is adjustable via the multifunction control panel, providing users of Tundra refrigeration air dryers with improved process control, increased power factor and significant energy savings.

Controlling the fan speed on the refrigerant circuit also presents the opportunity to eliminate components such as fan pressure switches which, over time, can sometimes become defective in compressed air dryers. The less moving parts, the more reliable the product.

Providing a robust and highly reliable build quality is a priority at Hi-line. For instance, following significant company investment, all Hi-line Tundra dryers now feature Scroll Freon refrigerant compressors, which offer the lowest possible power consumption and deliver cost-effective, long-life performance. The refrigerant system also takes advantage of liquid receivers, line dryers, thermostatic expansion valves and a series of safety features to protect the Freon compressor and its parts. In short, the design of Hi-line’s Tundra range centres on engineering specification, rather than budget.

As a point of note, Tundra dryers take advantage of R513a refrigerant in models up to and including Tundra 115 (115 cfm, 195 m3/hr capacity). A HFC/HFO blend, R513a refrigerant has no ODP (Ozone Depletion Potential) and a much reduced CO2 impact in comparison with the previous R134a refrigerant.

Tundra refrigeration air dryers with capacities up to 1530 cfm are available ex-stock from Hi-line’s centrally located headquarters and manufacturing facility in Burton upon Trent. The company also offers larger and higher pressure dryers (up to 40 bar) on short lead times.

www.hilineindustries.com