Compressed air solution for production facility

Australian recreation vehicle manufacturer Jayco optimises production at its new Dandenong production plant, with the aid of a customised energy-efficient compressed air solution from Champion Compressors.

In order to meet rising market demands, Jayco decided to consolidate its operations from 13 factories - split across three locations - to a single purpose-built 40,000 m² production facility in the Melbourne suburb of Dandenong.

Jayco chose Champion Compressors to conduct a compressed air audit and provide the compressed air solutions for the new facility. The audit on the existing factories was conducted using an Energy Monitoring Unit now known as AirMetrix. “AirMetrix is a comprehensive auditing tool that has the ability to monitor and log the performance of the entire compressed air system, taking power, pressure and flow measurements directly,” says Champion Compressors Sales Engineer Philip Tearle. “As well as taking direct measurements with great accuracy, AirMetrix also performs complex calculations to provide useful and meaningful data. This allows for the evaluation of a number of different options, before committing to a new compressed air system design.”

The results of the audit on the eight compressors across Jayco’s existing three sites were startling. Through a combination of compressors not having been adequately matched to the application and from accumulative leakage, over 60% of the energy used to generate compressed air was being wasted.

Using the results of the AirMetrix audit, Champion Compressors developed a compressed air solution properly matched to Jayco’s application. The solution comprises two Champion 90 kW VOC90 Series II variable output compressors (VOC) with sequence control. “Traditional lead/lag control wastes a lot of power due to the need for cascading pressure setpoints,” Tearle explains. “Sequence control allows the system to operate within a single narrow-pressure band, thereby saving energy.”

The VOC90 units were the key element of the solution. “Jayco’s air demand varies significantly throughout the day, so a compressor with a variable output is crucial to ensure demand can be met,” says Tearle. “Utilising two VOC compressors, which can run either in isolation or in parallel, further ensures all factory air demands can be met while the compressors continue to run within their ‘sweet-spot’ - their optimum efficient operating range.”

The audit also highlighted the need for a program of proper maintenance and service - both in the compressor house and the factory.

While the compressed air solution has been designed for the compressors to run at no more than 75% output for the current demand on site, the air receiver, filters and air dryer have all been sized to accommodate the increased flowrate from an additional VOC90 compressor - to be installed when required, due to a planned increase in compressed air demand on site.