The result is reduced energy consumption and improved air supply quality within the manufacturing plant. The positive environmental impact of the new installation has also been a contributory factor in gaining the company its ISO 14001 accreditation.
Celotex, based in Hadleigh, Suffolk, is recognised as the UK brand leader within the PIR (polyisocyanurate) category of insulation materials, a range of products considered by the construction industry to be the most cost effective and thermally efficient form of insulation. Dry compressed air is an essential factor in the continuous production process for insulation board assembly, which sandwiches PIR foam between two layers of aluminium foil or mineral glass tissue facer.
The decision was made to replace the two existing Atlas Copco ZT37 fixed speed, oil-free compressors and associated refrigerant dryers with a single air-cooled ZT75VSD FF machine incorporating an IMD heat-of-compression technology dryer. The installation provides the completely moisture-free air blanket required for the production process and, because of its variable speed drive feature that matches output to production demands, is a major factor in reducing energy consumption.
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Atlas Copco's Full Feature concept is a total installation − the compressor is a pre-wired and pre-piped solution, ready for use 'out of the box'. Integrating the IMD dryer and its variable speed drive enables the compact package to supply high quality dry compressed air at the lowest cost. The IMD adsorption dryer eliminates the moisture before it enters the air net to ensure a reliable process and a contamination-free end product.
No external energy is needed to dry the air, and as the dryer needs no purge air, no compressed air is wasted. The pressure drop through the dryer is minimal, which again cuts down its operating cost. The overall effect is to generate substantial savings in comparison to conventional types of dryer operation.
Commenting on the new equipment installation procedure, Jason Walker, Process Improvement Manager at the Celotex plant said: "I was very impressed with the speed and quality of Atlas Copco's installation operation. It allowed us to make a completely seamless switchover from the old plant to the new without any interruption to the production process. As for the projected energy savings, with the energy-saving VSD operation of both the compressor and integrated dryer unit, it looks like we can expect to gain at least £6,000 per annum over the next three years."
Developed and published by ISO (the International Standards Organisation) the ISO 14001 standard specifies requirements for organisations that wish to achieve and demonstrate sound environmental performance. These requirements compel the applicants to control the impact of their activities, products or services on the environment by implementing an environmental management system.
Jason Walker explained the benefits of his company's compliance with the ISO 14001 standard: "It fulfills core requirements for doing business within many public and private sector markets. It also demonstrates a responsible attitude and our environmental commitment. What's more, accreditation adds stature to our corporate image with both existing and potential customers, portraying a clear message to all concerned parties that this is a company devoted to high standards and continual improvement."
