What no compressed air!
September 1st 2004

Adam Battrick of Meech Static Eliminators looks at traditional drying applications and highlights how a fresh approach can reduce compressed air use and so reduce manufacturing costs

Almost 90% of manufacturing industries use compressed air in some aspect of their production.

With the introduction of the Climate Change Levy, these companies are looking even more closely at their energy bills and many have in place programmes that aim to strategically and efficiently reduce their compressed air consumption.

Over the years, Meech Air Technology has been working with industry on novel applications that will help companies manage the use of its compressed air both in terms of making it more energy efficient but also quieter and more ‘comfortable’ for their workforce to use. Out of this work has come one system that eliminates the traditional use of compressed air altogether.

The Traditional Use of Compressed Air For Drying Products Historically the most common method used to dry products travelling along conveyors was the use of compressed air. Initially, lengths of pipe with holes drilled along the length (20-25mm spacing) was the standard solution, it was both very costly and unproductive. There were two major drawbacks to this method: not only did each pipe virtually need its own dedicated compressor, but due to the spacing of the holes, the product was not fully dried and so ended the conveyor journey ‘striped’.

The Move Forward This is where Meech Air Technology, specialists in compressed air and drying techniques became involved. In a drive to help industry solve both the quality and efficiency issues of using this technique, Meech launched Its Air Curtain - an efficient compressed air driven product that can be used for drying across conveyors.

Air Curtains have two major advantages over drilled pipes. Firstly, they have a greatly reduced air consumption and entrain ambient air at a 25:1 ratio.

Secondly, the air is directed to the target in a continuous laminar blade, removing the striping that was experienced.

Air curtains are now routinely used throughout industrial processes, providing a more cost-efficient method of drying.

Jet Stream - Presenting Dramatic Cost Savings The Air Curtain was an important move for Meech, but as always, the demands of industry, fuelled by the introduction of the Climate Change Levy, meant that if costs were to be reduced further, a new method needed to be found.

Jet Stream provides a solution. It is a fan driven air knife system and due to the fact it does not use compressed air, companies achieve significant running cost savings, typically 80% or more.

The Jet Stream is powered by a high pressure fan unit. This air is then delivered to the “tear drop” manifold outlet, from which it discharges at velocities of up to 100 metres/sec.

The innovative stainless steel and hard anodised “tear drop” manifold profile provides two major benefits. Firstly, air exits the manifold in a consistent, laminar flow pattern that minimises turbulence, and secondly, the entrainment of potentially “dirty” ambient air is minimised.

Consequently a laminar blade of clean air is directed through a preset slot in the manifold accurately to the target.

Additional benefits of the Jet Stream system include its low noise levels, providing operator comfort, and lack of moving parts, ensuring low maintenance requirement.

However, the greatest benefit of all is the cost saving resulting from the ability to use fan-driven air in place of costly compressed air in a wide range of industrial applications.

Other Areas Where Compressed Air Use Can be Reduced For companies who use compressed air, one of the simplest and least expensive ways of saving costs is through the use of optimally efficient nozzles.

The simple installation of Meech Air Saver Nozzles can immediately reduce compressed air use by an average of 70% and increase air output by up to 25 times. To put financial figures on this: one 1/4” open air line, operating at 80 psi (5 bar) will consume 93 cfm (2632 Lpm) at a cost of approx £2000 per year. The adjustable Air Saver Nozzle operating at 80 psi (5 bar) will consume 15 cfm (424 Lpm) at a cost of approx. £325 per year. A saving of £1650 per year for every nozzle fitted.

A strong enough case to make even the most over-burdened FD take action.

In addition, the energy saving nozzles may perhaps eliminate the need for a new, more powerful compressor to replace an existing one that is struggling to cope with its current load.

Not only does the air user achieve increased air output, he reduces compressor wear as well, extending the life of the compressor still further.

More articles from Meech International Ltd: