Compressed air treatment : Roberts Plastics

Compressed air treatment : Roberts Plastics

PDF - 4 pages - 26/09/2018 - English

Download the study case (PDF)

Introduction or extract from the case study 

Roberts Plastics is a plastic bags manufacturer located in Toronto, Ontario. They have been in business since 1977. Discover in this case study how we provided solutions to Roberts Plastics Ltd to improve the performance of the compressed air network and the efficiency of manufacturing equipment. First by evaluating the compressed air treatment to the compressor, then analyzing the air distribution system design. To realize this case study, we met with Randy Roberts, the owner of Roberts Plastics.

Randy Roberts, owner of Roberts Plastics Ltd.

“Over the years, the increased production at Roberts Plastics created important challenges associated with the performance of the compressed air network, which is the lifeline of our manufacturing equipment [...] The challenges we faced with our compressed air system and the strains put on our compressor to meet the demand were not only affecting the consistency and quality of our products, it also was affecting our productivity, our energy consumption and the overall operating costs attributed by maintenance and unscheduled downtimes.”

Solutions to improve product quality and production efficiency (energy costs)

  • Install an air dryer and a proper pre-filtration at the compressor to remove the excessive water and dirt in the system
  • Design a closed loop compressed air network to deliver the right amount of air flow to each machine

Proper compressed air treatment at the compressor

Compressed air contains water vapor and different contaminants that need to be properly filtered in order to avoid downstream corrosion, to reduce wear and tear and to increase the service life of pneumatic equipment.

Air distribution system design

Most of the pressure loss in an air distribution system is due to inappropriate piping diameter and inefficient system configuration. The ideal pipe diameter should be calculated according to the total volume of air flow requirements and the total distance the air will travel. Closed loop systems are the most efficient type of system configurations. Octopus types of system designs will lead to excessive pressure loss. The advantage of the closed loop system is that the air traveling through several lines at a time. The air drops are supplied by two sources of compressed air allowing for smaller diameter pipes (reducing the cost).

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