Energy Savings in the Winter Months?
With CASCO USA, that may be true!
Winter brings with it many different concerns – moisture, bad weather, dropping temperatures. But an equally important winter concern is increasing energy consumption. Though this seasonal increase may not always be front of mind, it’s a big factor across an industrial plant. Processes like comfort heating, electrical lighting, even boiler operations may require additional energy to work in the cold. Operating in colder temperatures takes work! Focusing on just one of these high-power operations, such as your compressed air system, could yield significant savings across your entire plant.
Since air compressors are energy-intensive pieces of equipment, logically making changes to this system may cause ripple effects for the rest of your plant. Do you know how much energy your compressor requires in an average day? Do you know how much of that compressed air output is being used? If you don’t, that is an excellent place to start for savings. An air system audit will answer these questions and more. It is a minimally invasive process that involves adding electrical monitors to your system. These monitors will collect data from your system for a week or two. Once the audit is done, you’ll be able to better understand your actual demand levels, operation times, and air output. In short, you’ll see what you actually need and what you’re currently producing. Our engineers can use this information to target existing weak spots or build a new system entirely.
One of the best ways to conserve industrial energy is to work directly with energy professionals. They’ll be able to design an efficient system from the start to end. Fortunately for you & your compressed air system, CASCO USA has a whole team of individuals well-versed in system design. These AIRMaster+ Specialists are knowledgeable and ready to build you an energy efficient system that will last. Working with our energy team not only means you’ll have an efficient system for the winter months but one that yields savings year-round!
Not only is the overall design of a compressed air system important for energy savings, but the actual equipment matters too. On average, units from Kaeser Compressors offer greater energy performance than most comparable units. Of course, these energy reductions are only noticeable when using an appropriately sized machine. But working with our experts will make that happen! We’ll work to make sure you are getting the best unit to meet your systems’ demands. Our commitment to energy efficiency includes providing auxiliary equipment to ensure your system truly is running at its best. We don’t want anything to be missed.
Some new air systems may be so energy conscious that they qualify for rebates from the power company! We train our staff to know how to best achieve these energy rebates. We want you to achieve them if you’re eligible. Though the program usually only grants a one-time check, you’ll have built an efficient system along the way. One that will provide lasting energy savings on your electricity bill for years to come.
There are so many ways to save energy this winter, so what are you waiting for? Give our sales team a call and let’s start the process of designing you a new energy efficient energy saving compressed air system!
Frozen Treats & Compressed Air
Summer is here! There’s nothing more refreshing this time of year than a cold, sweet, frozen treat. It takes the edge off of the hot summer sun leaving a nice cool feeling in its wake. But have you ever thought about the process of making these delicious frozen goodies?
Compressed air plays a huge role throughout the manufacturing of frozen foods. A system might have pneumatically propelled conveyors, air in packaging lines, or regular blow off stations. But compressed air also plays a unique role in treats like ice cream. In fact, it’s often a very important ingredient.
Most frozen dairy products consist of some composition of milk, sweetener, eggs, and flavorings. But what separates a gelato from standard ice cream from soft serve? Often times the difference is the amount of “overrun” in the mixture. Overrun is the percentage of air incorporated into ice cream during the freezing process. This extra air makes the product expand and contributes significantly to the taste and texture of the finished product. Without the air, ice cream becomes hard, clumpy, and unscoopable.
Over several hours, air is carefully added into the slowly freezing ice cream. Ice forms alongside the air incorporation making the product creamy and consistent. The exact specifications of air incorporation will vary from product to product and manufacturer to manufacturer. All the same it is a very important step in the final ice cream creation.
Of course, when using compressed air for food products, it must be high quality and filtered. To meet food standards, a two or three stage filtration system can be used. Unfiltered compressed air may contain moisture, oil particles, dust, or other micro-organisms. None of these will add to delicious ice cream flavor! Luckily, working with a quality air system design team can ensure your system has all the drains & filters necessary to make the best final product. Oil-free compressors may also be a consideration for even better contaminant control.
Whether your treat of choice is an ice pop, novelty bar, or good ol’ fashioned ice cream cone, compressed air probably played a huge role in bringing it together. As you enjoy your refreshingly cool dessert, think about how it may be different without the use of quality compressed air.
6 Unusual Uses for Compressed Air
Compressed air is a huge factor in our everyday life, even if we don’t see it at first. Compressed Air is such a powerful tool involved in many of the products we use daily. From manufacturing operations to powering pneumatic tools, it exists all around us. It is even well integrated across the construction industry. But do you ever think about the other, less common uses of compressed air? Because there are a lot. Let this list of unusual uses for compressed air guide you into seeing its everyday nature.
Dry Cleaning: Air Compressors often power the entire gambit of dry-cleaning equipment. From solvent spraying to finishing presses, clean, powerful air is the key to a clean final garment. Regardless of the size of a dry-cleaning operation, you can almost certainly bet that an air compressor plays a role in the system.
Pharmaceutical Industry: In order to ensure production of vital medicines, the pharmaceutical industry has to be precise and clean throughout its process. Compressed air can help that to happen. Using specialized oil-free set-ups, compressed air may power conveyor belts, spray product coatings, maintain necessary pressures, or aid in the packaging stage.
Diving: Though not often thought of as an industry, diving work does rely on compressed air to accomplish tasks. In order to breathe underwater, divers use special tanks containing compressed air. This air must meet special breathing apparatus guidelines, beyond what is typical for most industrial applications. Without this filtered, contained air, underwater tasks for both recreational and professional purposes would look significantly different.
Theme Parks: Have you ever thought about what runs all of those fun heart-pounding, head-rushing rides that you love so much? More often than not, those thrilling rides are controlled by compressed air! Rotary screw air compressors provide the pneumatic powers to lift up, drop, and control the rides you know and love.
Trains: Locomotives still provide an important service across this country moving freight from one place to another. The trains are able to stop in a timely fashion by using air brakes. Compressed air controls pads or blocks which press against the wheels to slow them down as needed. In passenger trains, the compressors also help to open and close doors. Can you imagine what it would be like to have to open the heavy doors manually every time to let passengers on and off or to move between cars? In addition to these uses, the train’s suspension system also typically relies on pneumatics in order to make the ride a smoother experience for both passenger and cargo.
Resorts: What could be more fun that fresh powdery snow at a ski resort? Not much! That’s why in order to have that perfect powder finish, many resorts rely on the power of man-made snow for their resort’s finishing touches. Though it’s not easy creating the perfect artificial snow, having a strong air compressor to power your machine certainly helps.
Though these six unusual uses for compressed air are but a sampling of the many applications for compressed air worldwide, hopefully they give you a bit of an idea of why having good working air compressors are so important. They are so much more than just a tool for your construction project!
We’d love to hear more about the ways you use compressed air. Share in the comments below!
Compressed Air and the Candy Industry
It’s officially fall! Though you may notice the spooky mood, changing leaves, and cooling temperatures, one of the biggest markers of the new season is CANDY!
On average, Americans spend $2.6 billion on Halloween candy each fall, according to the National Research Federation. That’s a lot of candy! Naturally, candy production has to ramp up in the fall to keep up with the pace of demand. An important integration in the operations of almost any confectionery manufacturing facility is the use of compressed air.
Compressed air has a versatile ability to perform numerous production tasks. Overall, it’s a key component in a candy manufacturing system. From product blow off to ingredient aeration to packaging requirements, compressed air has a role throughout the entire process.
Sometimes it may even be used to pneumatically control equipment. For instance, many of the robotic elements in the candy-wrapping and packaging stations rely on compressed air to work. It allows for better control and precision of the machines, while also being a clean and efficient energy choice. Strong commitment to quality throughout the process means a delicious product awaits you on store shelves.
Though every confectioner’s individual setup differs depending on the unique needs of their product, there’s no denying the important role that compressed air plays. That’s why when Halloween season comes it is so important to have properly functioning machines. Regular maintenance, like discussed here and here, help to ensure that the important compressors keep working.
As you chow down on some delicious candy (pumpkin shaped or otherwise) this season, maybe you’ll think a bit more about the entire process. Putting together your yummy Halloween treat was no trick!
Do you have a favorite Halloween candy? We would love to hear about in the comments. Who knows!?! Maybe it’s even made by a CASCO USA-serviced machine.
Preparing Your Air Compressor: Fall Edition
The weather is changing. The days are bright; the nights are cool. It can only mean one thing – Fall has arrived. Though the spooky season and changing colors may be a comforting sign for many, it also signals that cold weather is on its way. Without proper preparation, this cold weather could spell disaster for your industrial air system.
The best way to ward off potential problems come winter is to perform the following maintenance tasks now. As the old saying goes, “An ounce of prevention is worth a pound of the cure.” In regards to your compressor system, that certainly holds true.
1. Know Your Maintenance Intervals
Every industrial machine is a little different in its needs. The specifics of an installation and its operating conditions will determine precise service needs. However, manufacturers do release guidelines to understand approximately how frequently certain tasks should be performed. You can usually find this information in a service manual or by contacting the manufacturer directly. Understand though, that certain environments may cause service needs to be sooner than the recommended intervals. CASCO USA also has a strong understanding of the typical service cycle. You can always ask us for advice on your system.
2. Check Your Filters
In addition to the ambient air, compressors suck in all the debris and contaminant surrounding a machine. The main job of the various filters is to sort through the hodgepodge of particles coming into the machine and stop them from traveling downline. Clean air is crucial to keeping your machine running efficiently. You need good air to use in your application. However, over time the filters become dirty and do not work as well. Changing your filters regularly helps to keep your machine in top shape and running as it should.
3. Drain Tank Condensate
As the temperature drops, it is always important to make sure that any lingering liquid is removed. Condensate, liquified moisture from the air, can freeze with low enough temperatures, just as any liquid can. Made of mostly water, condensate has a danger of freezing whenever the ambient temperature drops below 32 degrees Fahrenheit. The frozen condensate may cause problems for your unit, especially if the liquid has traveled into the air lines at all. For good preparation measure, make sure everything is in proper working order BEFORE the temperatures get too consistently cold.
4. Perform an Oil Change
Humid conditions like the summer often degrade the oil’s viscosity, which allows the oil to properly lubricate machine components. Without proper lubrication, the components may experience increased friction and stress causing premature machine failure. For heavy-use compressors, the oil should probably be changed quarterly.
5. Check weather strips.
Generally, a visual inspection is all that is needed to see if these are still in good operating condition. You want to make sure all insulation is keeping the heat inside. If you find any worn out areas, be sure to replace as soon as possible. Perform these visual checks several times until the cold days come to ensure your system truly is ready for winter.
Winterizing your compressor before temperatures drop too low is key to maintaining productive winter months for your system. If you aren’t certain of what fall maintenance your compressor needs, call your CASCO USA representative. They’ll be able to walk you through the process with their professional knowledge & expertise.
EVERY COMPRESSED AIR FORMULA YOU COULD EVER NEED (And then some)
Building a compressed air system is a delicate process, where multiple factors must be taken into consideration. In order to create a system that really provides the optimal amount of air and can meet demands requires having a team who truly knows compressed air. That knowledge comes from years of experience and practical applications….and tried and true compressed air formulas.
Since we know how important these formulas are both to our own operations and to your system, we’ve decided to compile some of the most useful and important formulas in one easy-to-find spot: our blog. Right here. That’s right! You’ve found it! All you have to do is keep reading.
Of course, if you have any questions beyond these formulas, our knowledgeable staff is availability to help. Call our main number at 1-800-728-5500 and ask to speak with one of our engineers. We’ll get you to the right person and the answer you need.
Without further ado, here is a list of important compressed air formulas.
Convert scfm to acfm:
acfm = scfm X (𝑃𝑠/𝑃𝑎) X [(𝑇𝑎+460)/(𝑇𝑠+460)]
Where:
- Ps = Standard pressure, psia (CAGI & ISO use 14.5 psia)
- Pa = Atmospheric pressure, psia
- Ta = Atmospheric Temperature, °F
- Ts = Standard Temperature, °F (CAGI and ISO use 68 °F)
Cost of Compressed Air Formula (At full load)
Cost = (𝑚𝑜𝑡𝑜𝑟𝑏ℎ𝑝 𝑋 0.746 𝑋 𝐻𝑟 𝑜𝑓 𝑂𝑝𝑒𝑟𝑎𝑡𝑖𝑜𝑛 𝑋 𝐸𝑙𝑒𝑐𝑡𝑟𝑖𝑐 𝑟𝑎𝑡𝑒) /𝑀𝑜𝑡𝑜𝑟 𝐸𝑓𝑓𝑖𝑐𝑖𝑐𝑒𝑛𝑦
Where:
- Cost = dollars per year
- Hours of Operation = one year of use
- Electric Rate = dollars/ kwh
Note: Motor BHP May be Higher than the Name plate HP (Generally 110%)
Belt Drive Equations:
Compressor RPM = (Motor Pulley Pitch Diameter X Motor RPM)/ Compressor Pulley Pitch Diameter
Motor Pulley Pitch Diameter = compressor pulley pitch diameter x compressor RPM / motor RPM
Compressor Pulley Pitch diameter = motor pulley pitch diameter x motor RPM / compressor RPM
Motor RPM = compressor pulley pitch diameter x compressor RPM / motor pulley pitch diameter
Note: Pitch diameter is slightly smaller than the pulley outside diameter (about where the middle of the belt rides). To measure the pitch diameter, subtract from OD:
| Belt Section | Approx. Pitch Diameter |
| A | OD – 0.25” |
| B | OD – 0.35” |
| C | OD – 0.40” |
| D | OD – 0.60” |
| E | OD – 0.80” |
Raising System Pressure:
C2 = C1 X (P2 + 14.7) / (P1 + 14.7)
Where:
- C2 = Required CFM to raise system pressure
- C1 = Existing or known CFM
- P2 = Desired Pressure
- P1 = Known Pressure
Pressure Drop:
dp = (7.57q^1.85L 10^4) / (d^5p)
Where:
- dp = Pressure Drop (kg/cm^2)
- q = Air Volume Flow at atmospheric conditions (m^3/min)
- L = Length of pipe (m)
- d = Inside Diameter of pipe (mm)
- p = Initial Pressure – gauge (kg/cm^2)
Unit conversion may be required. The following units are all equivalent values:
- 1 kg/cm^2
- 98068 Pa
- 0.98 bar
- 763 mm Hg
- 10000 mm H2O
- 2050 psf
- 14.2 psi
- 29 in Hg
- 394 in H2O
- 32.8 ft H2O
Air Storage in a Tank (Standard Cubic Feet):
𝑆𝐶𝐹 = [(𝑃2−𝑃1)𝑥𝐺𝑎𝑙] / [7.48 𝑥 14.5]
Where:
- P2 = final gauge pressure
- P1 = Initial Gauge Pressure
- Gal = tank size in gallons
Rule of thumb: For every 1 PSIG reduction in discharge air pressure, Compressor BHP (Brake horsepower) goes down 0.5%.
Definitions: PSIG means pounds per square inch, GAGE pressure. Gage pressure is the absolute pressure of something, with the atmospheric pressure subtracted. In practice, when someone gives a pressure in just “psi” they probably mean gage pressure. If they mean absolute, they should be using “psia.”
Note: This information is provided as a quick reference resource and is not intended to serve as a substitute for qualified engineering assistance. While every effort has been made to ensure the accuracy of this information, errors can occur. It is not the responsibility of CASCO USA should damage, injury, or misapplication occur as a result of using this reference guide
Summertime Compressor Concerns
Spring has yielded to warmer temperatures and bright sunny days. Summertime is officially here! Everything feels good and pleasant. But perhaps, not for your compressor.
Did you know that summer weather brings additional concerns for your compressor? Summer carries with it a host of considerations for your system, including higher temperatures and increased humidity.
High outside temperatures correspond to higher ambient temperatures surrounding equipment. The hotter a compressor runs the less efficient it will be. Hot temperatures make a compressor work harder to perform the same output. They slow down equipment and could even cause a full shut down due to overheating!
Increased summer humidity, means a greater amount of moisture trapped in the air. Without proper drying treatment, this extra humidity could be carried downline. This moisture has the potential to damage your products or processes.
Fortunately, there’s some key maintenance tasks you can easily incorporate into your routine to best prevent summer from wrecking your system. To keep your compressor working throughout the summer be sure to
- Clean Coolers — A common reason for an overheating compressor is a clogged cooler. Paying extra attention to these at the beginning of the summer can help to decrease problems later on.
- Check & Change Oil — Excessive heat can cause oil to break down and thicken, decreasing its ability to coat and lubricate moving parts effectively. Increased oil temperatures also lessen the oil’s secondary purpose of removing heat from the system. Fresh oil will keep your equipment lubricated and free of any contaminants.
- Changing Filter Mats — Ventilation is key to controlling summer temperatures, both in the room itself and throughout the equipment. Old filter mats may be congested with dirt, dust, or debris, preventing good air flow. Using appropriate, clean filters may lower operating temperatures and increase the life of both the compressor’s electrical components and oil.
- Clean Refrigerated Dryer Condensers — As a result of increased ambient temperature and humidity, there’s more moisture load and heat load on your dryer. Therefore, it is crucial to make sure that a dryer’s refrigerant condenser is properly cleaned. Otherwise, it won’t be able to accommodate the higher heat load. A clean condenser will ensure that the dryer provides the coolest air possible to a system.
- Check Drains – With more moisture moving through the system, it’s very important to check dryer drains in the summertime. Keep drains in good working condition. If a system has timed electric drains, the settings must be adjusted to open more frequently to account for the additional summertime discharge.
Stay on top of summer maintenance to avoid these concerns. Or call an experienced CASCO USA technician to perform the maintenance for you. We know how to handle these obstacles and mitigate problems before they begin.
Related articles:
Compressed Air Maintenance: Webinar Round-Up
Week 3
It’s week three here of our webinar round-up. There’s so many compressed air resources online!
This week our round-up focuses on perhaps the biggest element in keeping a compressed air system running: Maintenance. As weeks 1 & 2 have demonstrated, there are so many individual parts that make up a compressed air system. All these parts put in a lot of work, day in and day out creating air for your system. If they aren’t properly cared for, the equipment starts to malfunction.
That’s the underlying idea behind preventative maintenance – you must regularly care for equipment in order to prevent larger problems down the road.
Take the time this week to learn what good preventative maintenance should look like. Then take the necessary follow-up steps to implement it. Give our service department a call; they’ll be more than willing to schedule a time to give your system a once-over.
Topic: Compressed Air Maintenance
Maintenance & Reliability: Your Next Step to Energy Savings
Sponsored by Fluke
Produced by Plant Services
Maintenance & Reliability: What you need to know about starting a preventative maintenance program
Sponsored by Fluke
Produced by Plant Services
Maintenance & Reliability: Maximizing work processes with a predictive maintenance program
Sponsored by Fluke
Produced by Plant Services
Thanks for stopping by!
Don’t forget to read our other articles about Compressed Air Maintenance:
- Servicing Air Compressors at CASCO USA
- The Art of Compressor Maintenance
- New Year, New Service Agreement?
Building Systems: Compressed Air Webinar Round-up
Week 2
We’re back! And we’re happy that you’ve decided to visit us again. At least virtually.
This week we’re continuing our round-up of the best compressed air webinars. This time focusing on webinars that really get into the nitty-gritty of building a solid compressed air system. As our staff has always advised, compressed air systems are COMPLICATED! But luckily, with good comprehensive background knowledge and the right tools, the process of building systems can become a little less so.
Of course, these webinar only seek to give you a taste of some of the most important consideration factors. For more detailed assistance, our full staff remains reachable. Give us a call, send us an email, or fill out our online contact form. Any method will put you in touch with knowledge, reliable compressed air assistance.
So without further ado, here’s our top webinar picks centering on building systems that are well-constructed.
Topic: Building Systems
Comprehensive Compressed Air Assessments: The 5-Step Process
Sponsored by Kaeser Compressors
Produced by Plant Services
Compressed Air: Examine Key Design Considerations that Contribute to an Efficient Compressor System
Sponsored by Kaeser Compressors
Produced by Plant Services
5 Tips on Optimizing VFD Air Compressors
Sponsored by Kaeser Compressors
Produced by Compressed Air Best Practices
Missed our first round-up about system energy savings? Don’t worry, check it out now. And come back weekly for more insights & learning materials to expand your mind and your compressed air knowledge. There’s even resources on our website for you to engage with us daily, if you wanted. You can never have too much compressor knowledge!
System Energy Savings: Compressed Air Webinar Round-up
Week 1
Though the recent societal changes brought on by COVID-19 are challenging and disruptive, they may present a positive, unexpected opportunity. Maybe you finally have some extra time to learn more about your compressed air system!
Perhaps your normal routine is completely out-of-wack at the moment. That’s ok. The disruption could be a chance to take some time and really explore in-depth some new industrial topics. It’ll pass the time and leave you with greater knowledge than before!
To help you in this endeavor, we at CASCO USA are going to devote the next few weeks of our blog to round-ups of some of the best webinars in the compressed air industry. Each week will center around a different compressed air topic.
We invite you to take some time, watch some videos, and learn some new information. Who knows what you’ll uncover in the process?
To start us off, this week’s round-up will focus on “System Energy Savings”.
Who doesn’t want to save energy and money? Fortunately, there is lots of valuable information exploring precisely that! We’ve compiled some of the most useful webinars and insights about creating energy savings in a system below.
Of course, our very own in-house engineers are also still available for consultation, should you need a little more energy saving direction. Simply call us and ask for engineering assistance.
Topic: System Energy Savings
Techniques for Determining Savings from Aeration Blowers
Sponsored by Kaeser Compressors
Produced by Blower & Vacuum Best Practices
How to Improve Energy Efficiency in a Compressed Air System
Sponsored by Kaeser Compressors
Produced by New Equipment Digest
7 Common Mistakes that will ruin your compressed air system efficiency
Sponsored by: Ron Marshall
Produced by: Compressed Air Best Practices
Oversizing: A Widespread Compressed Air Problem that is costing you time & money
Sponsored by: Kaeser Compressors
Produced by: Plant Services
LIVE May 20th at 2 pm EST
That’s all for this week. We encourage you to visit us again next week to continue your compressed air system learning and to check out all the existing resources on our website in the meantime.