Holistic approach

“Ingersoll Rand’s holistic total system approach to compressed air goes hand-in-hand with the Industry 4.0 approach leveraging the advances in compressor technology, specialised know-how, analytics and control expertise to provide our customers with a smart manufacturing solution that meets their individual requirements,” said Luca Ferrari, energy service support manager at Ingersoll Rand. “We use our expertise to turn liabilities of an inefficient system into a performance advantage and find new ways of creating value, productivity and efficiency gains for our customers.”

Tekfor Italy was looking for ways to modernise its compressed air system in the Avigliana manufacturing site with the goal to achieve energy cost reduction, lower the total cost of ownership and improve service quality and reliability. The ageing setting, based on overcapacity oil-free compressors, was not meeting their desired efficiency levels and, when approached, Ingersoll Rand Compression Technologies and Services was able to partner with Tekfor to conduct a full analysis of the existing system and provide tailor-made recommendations and cost-effective options for the required improvements. 

Ingersoll Rand began the project in the end of 2015 with learning and understanding Tekfor’s plant’s individual needs for compressed air, following with a detailed assessment of not just the particular compressors or components but the entire existing system and its configuration. 

Based on the assessment, Ingersoll Rand provided Tekfor Italy with a tailored solution that in February 2016 allowed for the replacement of the oil-free compressors with oil-flooded units and the creation of a completely new compressor room with new dryers, piping and control system. The newly installed ISO12100 certified oil-flooded compressors are fixed speed R160ie, R132n with variable speed drive and a refurbished IRN160K-CC to serve as back up. 

To lower Tekfor’s cost of ownership associated with the new system, Ingersoll Rand offered the customer an alternative, low capital expenditure solution based on the long-term rental of air-compressors. Along with the opportunity to note immediate capital savings and leverage the operating expense budgets, this customer centric approach has further contributed to the improved service quality and reliability of the new system.