Canadian glass manufacturer Trulite manufactures high-end commercial glass products. The production of laminate glass, which requires the use of an autoclave, is especially energy-intensive. To reduce production times and fill times of the autoclave, the autoclave system is constantly pressurized by two 150 hp compressors.
With rising energy costs and a problematic compressed air system, Trulite worked with Airleader and Compressor Management Inc. to perform a compressed air study. The study identified several deficiencies in the autoclave and plant side low-pressure system. The most obvious issues were:
- Lack of storage causing large pressure swings.
- No control of the compressors causing excessive idling.
- Grossly oversized plant VSD compressor on the lower pressure side of the system.
An Airleader Master Controller was used to analyze the system and simulate the best options for configuration and operation of the two systems. Following changes, the system runs trouble-free with online visualization of the entire system ensuring reliability and peace of mind.
The energy reduction of the system is an astounding 83% decrease in kWh, or 2,343,400 kWh reduction. Additionally, at the completion of the project Trulite received a utility rebate for $147,428 CND.
To read the complete study, including graphs and schematics, link to the study published in Compressed Air Best Practices Canadian Glass Plant Optimizes Autoclave Compressed Air
(this link will open a new window and direct you to Compressed Air Best Practices website)