The Situation
The customer, a cardboard packaging factory, was having persistent issues with their dryer not performing as expected and components on the line were failing as a result of water and contaminants entering the pneumatic system. Over the course of a year, an air motor had been replaced ten times, costing £11,470.
The site had an existing refrigerant dryer in place; however, compressed air contamination issues persisted. A second dryer was considered to resolve the problem, but the implementation of Expel removed the need for additional equipment. This approach delivered a more cost-effective solution while also reducing environmental impact.
Benefitting from being a HAYLEY DEXIS Onsite customer, assistance was sought directly through the Onsite team member, who is able to call upon technical personnel at HAYLEY DEXIS and the supply partner network.
The Solution
HAYLEY DEXIS invited Original AVG to visit site and perform a survey and to demo the Expel filtration system. After being impressed by the credentials of Expel, the customer accepted a proposal for eleven filters which would be installed in locations prior to air entering the machine.
The initial outlay on the purchase price of the Expel filters was less than the cost of a new refrigerant dryer, representing an immediate £4000 cost-saving against another potential solution to the issues being faced.
"PERSISTENT ISSUES WITH THE DRYER SECTION OF THE PLANT HAVE BEEN ELIMINATED"
The Result
Using several informed asumptions around the machinery in place and its power consumption, the plant’s 24/7/363 run-time, the customer’s electricity cost of 8p per kWh, and the UK Govt. standard carbon conversion factor, the Expel filters now in situ are saving £2,100 per year, equating to 5.4 tonnes of CO2e.
With their ten-year guarantee, the Expel compressed air filters will deliver £21,000 in energy cost-savings as well as a 54 tonne reduction in CO2e emissions, over their lifetime. By eliminating the issues with contamination of the system, the filters will prevent further premature failures to components including the air motor that was being replaced every six weeks, on average. This will save the customer £11,470 over the next ten years.