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Case Study: Stationary compressor upgrade

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Sullair Australia supplied and installed a new compressor solution recently for a Melbourne-based manufacturer of sheet metal components.

Located in Mulgrave in the South Eastern suburbs of Melbourne, Britannia is a major manufacturer of sheet metal components for a wide range of industrial sectors.

Britannia’s operations relied on a stationary electrically powered compressor, which began experiencing problems in April. With its supply of quality compressed air impacted, Britannia immediately requested assistance from Sullair’s service department, which organised for an emergency technician to visit the site.

Since the compressor’s air-end had seized, Sullair supplied a portable diesel air compressor as an interim measure to prevent production downtime till a more permanent solution could be found. Sullair also organised a site and air-compressor assessment to address Britannia’s long-term requirements for a stationary air compressor. Following the assessment, Sullair developed a detailed plan for the new compressor installation, and recommended that the temporary diesel compressor ‘take the load’ during the process.

The installation was completed seamlessly with the smooth transition from the temporary compressor to the new ShopTek compressor managed by Sullair.

Britannia’s James Burt commented that the ShopTek compressor met all their requirements for affordability and energy efficiency.

Sullair’s package for Britannia included the provision of an electrically powered, energy-efficient ShopTek 30 compressor, complete with mechanical installation. Key features include MEPS2-compliance; rated at 30kW, with 79.2l/s free air delivery at a working pressure of 8.0bar; intelligent electronic controls; space-saving energy-efficient design; and choice of configuration options to allow each compressor to be tailored to the end user’s exact requirements.

The deluxe monitoring capability of the ShopTek compressors ensures exceptional performance and energy efficiency, with the ability for all essential parameters from the controller to be monitored remotely through Modbus connectivity.

Transducers are used to regulate pressure, minimising off-load running and reducing over-compression, while enhancing performance and efficiency.

ShopTek motors also utilise Sullair’s proven air-end, which optimises efficiencies over a wide range of operating capacities by matching the air-end discharge port to the volume/operating pressure ratios. The air inlet design also avoids preheating the inlet air to deliver additional savings. Longer air-end life is ensured with the controlled pressure lubrication and bearing fluid reservoirs assuring a reliable supply of fluid to rotating elements.

ShopTek compressors further improve environmental performance through the use of Sullube, a biodegradable lubricant that has a life of up to 6,000 hours.

The leading compressor company prides itself on delivering the ‘Sullair experience’ to every customer. Highlights include installation, commissioning, and routine and programmed maintenance services; 24/7 breakdown service; hands-on and online training; continuous evaluation and monitoring of the customer’s compressed air system to ensure the compressed air supply/demand requirements are optimised for cost efficiency; and security of reliable 24/7 support through a network of more than 15 locations Australia wide along with dependable availability of spare parts at short notice.

In addition to the service benefits offered by the Sullair experience, the Sullair ShopTek compressor delivers key benefits to Britannia. With over 70 per cent of the lifecycle cost of a compressor typically going towards energy use when measured over a ten-year lifespan, the energy efficiency of the ShopTek compressors improves environmental performance and reduces the overall cost of ownership.

In this particular project, Sullair’s success came from its ability to provide a one-stop solution to Britannia by responding rapidly to its existing compressor problems; providing an interim solution to keep the facility in production; designing a tailored long-term solution; supplying, installing and commissioning the new ShopTek compressor; and providing training to Britannia’s production crew at no extra cost.

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