June 2021

14 | Plant & Works Engineering www.pwemag.co.uk June 2021 Advertorial How the compressor industry has changed over the past 40 years S ubstantial investment in R&D and manufacturing techniques, plus a constant drive for innovation, has ultimately turned compressed air from being just an alternative power source into an essential fourth utility, supporting the smart factories of the 21st century and playing a crucial role within manufacturing processes and engineering productivity. A string of technical developments from leading compressor companies, such as Atlas Copco, included the first oil-free, electrically driven screw compressor in 1967, thereby opening up new opportunities for pure air for applications such as medical care and the food industry. 1994 saw the launch of the first fully- integrated variable-speed drive compressor unit – then a revolutionary new product that made possible a whole new standard of energy efficiency in the industrial workplace. It is now recognised as the greatest energy saving innovation in the history of compressed air developments. Further innovative solutions over subsequent years have seen energy consumption, noise levels and footprint being reduced by previously unimagined levels, and compressors being connected via the internet into a factory’s network. VSD developments Now, in the form of the latest advanced VSD+ specification compressors, matching air output to user demand, compressor owners are able to achieve outstanding savings of up to 50% of their installation’s energy requirement. Built with smaller, vertical aspect footprints to save production space and offering the cost benefits of in-house designed components, the principal game-changing innovative feature of these latest compressor concepts is the unit’s close-coupled drive train. The combination of a high-efficiency IP55 motor and a technically advanced, asymmetric compression element offer the attributes of total functional reliability, smooth operation, productivity gains, increased uptime, and lower maintenance costs. An additional benefit of today’s increased compressor efficiency is that it also lowers emission levels and allows for a more sustainable production. As a result, a new-tech compressor does not just improve a company’s bottom line, it also helps to protect the environment. Greener production Over 70% of companies are continuing to prioritise sustainability and environmental management issues. Many of this number will include production companies with compressor systems that have taken all the right steps and benefited from the adoption of green technology. Adopting good practice and adapting or replacing their compressed air system with new technology, energy efficient solutions is their guarantee of a reliable and sustainable air supply to aid productivity, minimise costs, and promote a greener, cleaner environment. Smart communication Leading compressor manufacturers’ solutions are not just ahead in terms of efficiency and reliability but also of connectivity. Knowing the status of compressed air equipment at all times is the surest way for plant managers and maintenance professionals to spot any developing problems. On the positive side, it is also possible to uncover potential energy savings and achieve maximum uptime of both compressors and the production lines they support. The role of connectivity with advanced monitoring and control systems is an area that has become increasingly important because it not only makes the compressor easier to operate but also increases both efficiency and reliability. Making smart use of connectivity, data monitoring and business intelligence, helps air users get a better view of their maintenance needs, maintain production uptime and improve their operating costs, wherever possible, by minimising energy consumption. Technology of the future For compressor users, the move toward connectivity and digitalisation in the era of Industry 4.0 is now a reality rather than a distant future. At the cutting edge of this new technology is the use of OPC UA communication technology in compressors, the common language that allows equipment items to “speak” with each other. It is technology that ensures that an operation runs smoothly by ensuring that every item of equipment can effortlessly communicate with every other device. Atlas Copco is the first manufacturer to release its initial series of compressors that speak this universal language. In the future it will be possible for compressor users to install this technology retroactively and enjoy all of its benefits. Starting back in the 1930’s when the first rotary screw compressor was introduced – based on an improved version of Alf Lysholm’s helical element concept – the role of air compressors in industry has now shaken off its Cinderella image and seen radical changes in performance, reliability, energy efficiency and cost of ownership. Atlas Copco Compressors Tel: 0800 181085 Web: www.atlascopco.co.uk/compressors