Wireless air treatment.

Emerson is creating sustainable solutions for their customers with CoreTigo's wireless industrial automation technologies. The collaboration tackles the challenges of Compressed Air Management in machinery, ultimately reducing energy waste and CO₂ emissions, while enhancing maintenance efficiency and operational processes.

The solution enhances Emerson’s AVENTICS high-end air flow and pressure regulation units, by supplementing and retrofitting these into wireless units with CoreTigo’s IO-Link Wireless products. Named the “Energy Saver”, the solution provides a holistic approach that creates the most cost-efficient and simple way to enhance production lines with an advanced air treatment application.

The Aventics AF2 Air Flow Sensor and EV12 Pressure Regulator are each connected to CoreTigo’s IO-Link Wireless Bridge (TigoBridge), which instantly converts it into a wireless device with industrial-grade communication capabilities. The TigoBridges transmit wirelessly to CoreTigo's IO-Link wireless gateway, while the Energy Saver provides a constant stream of airflow from “Floor to Cloud™” for analysis and monitoring. In addition, the solution from EMERSON controls the pressure regulation unit independently from the machine’s PLC or the air compressor, allowing intelligent operation without machine downtime or PLC programming. Maintaining control over air pressure is essential for ensuring the machine remains in a stable and secure state during periods of inactivity, while also minimizing pressure to prevent unnecessary air wastage.

The Energy Saver solution offers a range of benefits, including a reduction in CO₂ emissions through minimized air leakages and optimized machine idle mode operation. It ensures sustainability and compliance with regulatory standards, promoting environmentally friendly manufacturing. By preventing prolonged non-optimal air flow, it minimizes unplanned downtime and maintenance requirements, while reducing cable wear and tear thanks to its wireless setup. Its simple deployment requires no modifications to the PLC setup or complex cabling layouts. Furthermore, it contributes to cost savings by lowering energy expenses and reducing maintenance and deployment costs overall.

Emerson’s IO-Link Wireless based Energy Saver solution was developed with a major food and beverage manufacturer and is expected to continue revolutionizing various industries in the near future.

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@CoreTigo @EmersonExchange @Emerson_News @EMR_Automation @mepaxIntPR #PAuto

Fan, pump and compressor drive.

Delta's Open-Loop Variable Torque Standard Drive VP3000 for fan, pump and compressor applications has just been launched. Itis specially designed to enhance fluid machine operation efficiency and reduce inverter harmonic distortion for a wide range of fluid applications. The VP3000 series offers excellent performance and stability with support for high-efficiency motors including induction motors, permanent magnet motors, and synchronous reluctance motors from 0.75 to 630kW. The new drive will be among the highlights at the Delta booth at Hannover Messe 2023 (Hall 11, Stand C20).

“For fluid machine operation, the customers are now looking for high efficiency to reduce energy and CO2, lowered harmonic distortion and user friendly functions. By offering greater power density of 23% lower cabinet volume on average, and low harmonic distortion of down to THDi 35%, the VP3000 is able to satisfy regulations across Europe, the Middle East, and Asia,” said Landers Yeh, Product Manager, Industrial Automation Business Group, Delta Electronics EMEA region. “We’re confident this new variable-torque drive is going to be very competitive.”

Highest Standard and Low Harmonic Distortion.
The new VP3000 drives from Delta come with an array of integrated safety features. Safe torque off (STO) SIL3, the highest safety integrity level that applies to machine systems. Built-in EMC filters provide electromagnetic compatibility up to C2/C3. The drive is resistant to moisture and dust with coating 3C3. By using film cap topology to replace traditional electrolytic capacitors, Delta was also able to lower the drive’s harmonic distortion down to 35%, far below the EN 61000-3-2 standard which specifies a total harmonic distortion (THDi) of less than 48%.

Energy-saving and User Friendly Functions.
Compared to the general motor drive, the higher power density of the VP3000 allows for a 23% lower cabinet volume on average. In some cases, the volume of the unit can be decreased by as much as 55%. The high-power models can also mount durable and easy-to-maintain floor-type modules, which increase space utilization and simplify assembly for easier and faster operation. It also helps improve motor productivity and efficiency, reducing carbon emissions for environmental sustainability as a critical part of device-based energy saving.

Equipment in the heating, ventilation, and air conditioning industry as well as water treatment facilities will benefit from the drive’s advanced features, which enable the movement of fluids using fans and pumps. The new drive also has a predictive maintenance feature for key components, which helps users pre-schedule service to ensure the stable operation of machines.

@mepaxIntPR #deltaww #PAuto #HM23

Accurately measure and log dew point data.

The Extech RH600 Dew Point Meter for accurate and fast dew point temperature measurement primarily positioned to prevent problems associated with water vapor in compressed air systems has been announced by Teledyne Flir.

As part of a predictive maintenance program in manufacturing environments, the Extech RH600 provides measurement down to -50°C (-58°F) with an accuracy of ±2 °C (±3.6 °F) over the entire range pressure, up to 20 bar. The instrument is ideal for monitoring dew point across long periods of time, including for monitoring switch behavior within the drying process and better optimizing energy consumption.

“For inspectors who require the convenience and freedom to inspect multiple positions within a compressed air system, the Extech RH600 provides the ideal form factor at a competitive price to capture accurate readings and then data log that information as part of an integrated predictive maintenance program,” said Rob Milner, director of business development, Teledyne FLIR. “The Extech RH600 is also optimal for low-humidity measurement with high accuracy, but should the sensor get wet, it can withstand the condensation and fully recover for future use.”

The included RH601 dew point probe provides accuracy and long-term stability. Users can directly insert the probe sensor into the compressed air system through a G half-inch thread, ensuring reliable readings with increased peace of mind, knowing the probe will dry quickly after moisture contact. The highly sensitive probe provides inspectors the ability to measure relative humidity at less than 5 percent and with high accuracy (±0.025 percent).

Data Logging for Predictive Maintenance.
Users can easily monitor dew point on the built-in color graphical display with a menu-based user interface. They can program high/low set points for temperature as well as relatively humidity and dew point with visual and audible alarms. The device also enables logging and transferring up to 32,000 datasets to a PC in CVS format via a USB cable connection. The easy data transfer provides inspectors all key datapoints to create inspection reports for colleagues and clients, as well as to integrate the data into broader predictive maintenance initiatives that consolidate and analyze data across multiple inspection types and equipment.

The Extech RH600 consists of the RH601 dew point probe, AC adapter, micro-USB-to-USB-A cable, a 3.7 V Li-ion battery, and a hard case for storage.

@flir @mepaxIntPR #PAuto #Manufacturing

Moisture in compressed air dryers.

Michell have issued a new paper on Critical moisture measurements for compressed air dryers.

Compressed air supplies are a necessity for industrial applications around the globe. In Europe alone, it is estimated 10 percent of all industrial electricity consumed is used to produce compressed air. Compressed air can also be used as a safe alternative power source in hazardous locations where there is a risk of fire or explosion, such as mines and oil rigs.


When warm compressed air leaves the compressor, it contains a high level of water vapour, and drying is a necessary part of the process. Any water vapour in the system will condense on cold surfaces and create the risk of corrosion or blockages.

Drying is a crucial part of the compressed air system and there are three options to choose from:
• After coolers (usually combined with another form of dryer)
• Refrigerant dryers
• Desiccant dryers

Dew-point measurements increase the efficiency and economy of drying – read the full article here to find out how dew-point dependent switching (DDS) saves money and ensures the quality of compressed air supplies.

• Michell INstruments are marketed in Ireland through Instrument Technology.

@Michell_Inst #PAuto @Instrum_Tech

Manager in Compressor Division.

Atlas Copco Ireland has announced the appointment of Tom Van Gaal as Business Line Manager for its Compressor Technique Service division.

Tom Van Gaal

After four years in the role of Technical Support Specialist in the Atlas Copco Airpower factory in Belgium from 2012 to 2016, and a brief spell as operational analyst with Atlas Copco Argentina in 2014, Van Gaal occupied the post of Global Process Engineer at the service division headquarters in Antwerp (B). Tom carries an MSc degree in Mechanical Engineering and Applied Economics. With all this, he brings a broad range of academic, operational, process and product development experience and skills to the role.

Commenting on his appointment, Tom Van Gaal said: “After six years in Belgium, where I worked on ensuring the continuous improvement of our products and processes, I am very much looking forward to working directly with our customers, in Ireland. My goal is to further strengthen Atlas Copco’s aftermarket business and actively contribute to the sustainable and profitable growth of the company and that of its customers.”

Tom’s focus will be to combine the existing operational experience of the team in Dublin with Atlas Copco’s new state-of-the-art ERP and CRM solutions, in order to deliver on the company’s promise of offering reliable and innovative services, along with the aim of maintaining and increasing their customer’s productivity.

Van Gaal believes that in tandem with rapidly evolving technological developments, which have improved the efficiency and performance of Atlas Copco’ equipment, it is equally vital to maintain investments in the competence of the company’s team.

“I intend to place great emphasis on continuous training of all our staff, to live up to our customer’s expectations of having the most skilled and knowledgeable service workforce available to them, 24/7."

In his leisure time Van Gaal is an active sports enthusiast and both played and coached soccer in Belgium. He is equally keen on rock climbing, golf and snooker, and is developing an interest in GAA Irish sports and rugby. He enjoys travelling and is looking forward to exploring the beauty of the Irish countryside, not to mention his forthcoming marriage later this year.

• See also New HQ opens in Dublin's pharma district. (7/3/2018)

@AtlasCopcoUKIRE  #PAuto #Ireland  @AtlasCopcoGroup

New HQ opens in Dublin's pharma district.

Atlas Copco Ireland has officially opened its new state-of-the-art headquarters in Dublin. The building is an ample 560 m2 in size and will be the permanent new workplace for the company’s 32 local employees. The move provides a wide range of benefits, including excellent transport links, an open-plan office area to enable staff to communicate and work more effectively; as well as a large purpose-built workshop and warehouse area that ensures customer requirements are met efficiently.

Micheál McGuinness - Country Manager for 

Compressor Technique and Anna Brand,

The Swedish Ambassador to Ireland.

The grand opening of the building, which is located in the heart of West Dublin’s Pharmaceutical district, took place on 26th January and was host to The Swedish Ambassador to Ireland, Her Excellency Anna Brandt, and to Market Area Director at Business Sweden, Gustaf Bergström.

The special guests were hosted by senior spokespeople from the global Atlas Copco Group, which is the world’s leading provider of sustainable productivity solutions. This included Andrew Walker – President of the Atlas Copco Power Technique business area, Alain De Dauw - Vice President of Human Resources for the Atlas Copco Oil Free Air division and Alexander Pavlov - Former Country Manager for Atlas Copco Ireland and current General Manager for Atlas Copco Compressor Technique in the United Kingdom. This was in addition to all of the management and staff who will be situated at the office in Dublin.

The advantages to be gained from the move will play strongly into the company’s customer focussed vision, as Micheál McGuinness, Country Manager for Compressor Technique at Atlas Copco Ireland commented: “We would like to take this opportunity to thank all of our customers, past and present, for their custom over the years and look forward to welcoming them to our new head office in Dublin. Our mission is to help customers protect their investment in high quality machinery, avoid unexpected situations and increase uptime – a goal we feel we are expertly placed to fulfil even more effectively from our new premises.”

210 m2 of Atlas Copco Ireland’s Head Office is dedicated to a large workshop and warehouse area. The purpose-built workshop facility provides a safe working environment for service technicians and contains state-of-the-art power tools and lifting equipment to ensure quick turnaround times when performing maintenance and overhauls of major pieces of customer equipment; such as compressor blocks, industrial air elements and gear box assemblies.

Meanwhile, the warehouse area contains a generous amount of racking space to store equipment, together with an improved flow of parts inventory to further ensure Atlas Copco Ireland is able to provide the best possible lead and service times for customers and maintain its position as a market leader.

Atlas Copco Ireland foresees many aspects of its new headquarters that will offer benefits for both staff members and customers alike. For instance, the building’s convenient proximity to the M50 motorway will ensure that deliveries are more efficient and travel is easier for anybody visiting the company’s head office.

In addition to the external benefits of the location, the newly overhauled open plan office enables team members to fully embrace an activity based working style; which has been shown to lend itself to easier communication and increased productivity.

The opening ceremony was attended by all of the Atlas Copco management and staff 

who will be situated at the office in Dublin. (Click to enlarge)

@AtlasCopcoUKIRE #PAuto #Ireland #Sweden

Appointment to strengthen compressor business in Ireland.

Alexander Pavlov has been appointed as Country Manager for Atlas Copco's Compressor Technique business in Ireland. In this new role, he will continue the implementation of an aggressive strategy to strengthen the position of Atlas Copco as a market leader in Ireland.

Alexander Pavlov

Pavlov states his mission as: “To make sure we grow even stronger than the local economy in Ireland, meaning that we gain market share in the segments where we have not traditionally performed. In the last couple of years, Atlas Copco has invested a lot in the Ireland organisation, especially in the sales and marketing team. Now we have a much stronger presence in the industrial market and the economic indicators are positive.”

These last two factors, plus a number of new compressed air, industrial gas and rough vacuum products, including the recently launched GHS VSD+ vacuum pump that offers average energy savings of up to 50%, makes Atlas Copco Compressors’ Irish sales organisation well-armed to focus exclusively on growth. As Pavlov explains: “All of our products and services have one property in common, which is that they offer customers sustainable productivity. On top of that we have greatly improved our operational efficiency following the recent implementation of new state-of-the-art ERP and CRM systems.”

The aftermarket business is one of Pavlov’s main focus areas. Atlas Copco’s local organisation in Ireland has a highly experienced service team and operates advanced planning systems, which allows it to exceed customer expectations when providing service and supporting uninterrupted customer productivity and energy efficiency. “Our strategy is to convince more customers to subscribe to a service contract with Atlas Copco, which will enable them to keep maintenance costs at a stable and predictable level, avoiding any unexpected situations,” commented Pavlov.

Pavlov’s first impressions of the team in Ireland were very positive. He says, “I am very impressed with the team of 31 people we have in Ireland. We have a great mix of experienced mature colleagues and young high potentials. It's a great pleasure and honour joining such a team.”

Pavlov is a Belgian citizen. He graduated as a software engineer in St Petersburg Technical University and then worked in the Alcatel group, prior to joining Atlas Copco in Antwerp in 2003. He held the positions of Information Systems Project Manager and Product Marketing Manager, and for the last four years has been working as Regional Business Line Manager for Compressor Technique for South East Europe, based in Greece.

Outside of work, Pavlov dedicates most of his time to his family, with three sons aged between 4 and 16. He follows many sports with a particular interest in football, and also likes history, classical rock music, and playing guitar in his spare time.

Air compressors & quality air products for Ireland.

C&L Industrial Ltd, based in Galway and Dublin (IRL), has been appointed as an authorised premier distributor for Atlas Copco's range of industrial air compressors, quality air products and spare parts.

“This new appointment complements our established sales network in Ireland, through which we continue to provide valuable compressed air solutions to industrial users in the country. C&L share the same values as Atlas Copco and as such, make the ideal partner to help us take our business forward" said Sean Fairest, Atlas Copco’s Country Manager-Compressor Technique.

LtoR:Sean Fairest, Atlas Copco, 

Colum Whelan, C&L Industrial, 

Tom Dowling, Atlas Copco

C&L Industrial’s appointment as an Atlas Copco premier distributor gives the company access to the range of GX and GA rotary compressors, including variable speed drive models, SF scrolls and L range of reciprocating compressors, with the addition of N2 nitrogen generators. C&L will also distribute Atlas Copco’s comprehensive range of air purification accessories, including dryers, filters and oil-water separators, as well as genuine Atlas Copco spare parts.

C&L was founded in 1998 as a compressor sales, service and repair organisation by Managing Director Colum Whelan, who heads a strong family-orientated team of four senior sales specialists and employs a staff of eight, comprising service engineers and administration personnel that have been in the compressed air business for most of their careers.

According to Colum Whelan the company has built on that foundation and with access to Atlas Copco’s technical knowledge and support, plus the Industrial Air range of compressors, ancillaries, service plans and parts, now represents one of the leading compressed air houses in the Republic of Ireland: “C&L’s continued growth stems from our focus on customer efficiency and productivity. Our aim is to help them achieve these results through improved performance and equipment reliability as well as reduced installation, running and maintenance costs.”

The total service support available from C&L Industrial includes design, installation, consultancy, compressed air equipment servicing, repairs, maintenance, on-site workshop facility, hire schemes and energy management, together with audits and testing of compressed air systems.

Energy recovery units!

Atlas Copco has announced a complete re-design of the stand-alone, retrofit energy recovery units for its GA compressors. The new ER range now offers improved performance and a smaller footprint.

As much as 94% of the electrical energy used by industrial compressors is converted into heat and lost through radiation in the compression process. The remaining 6% is converted into compressed air heat losses. The new ER units recover up to 94% of this thermal energy to heat water up to 90°C for a number of process and domestic applications such as showers or central heating.

The ability for application industries to generate pre-heated water via Atlas Copco’s ER energy recovery systems helps reduce the costs of traditional energy sources and minimise the environmental impact of their CO2 emissions.

Development of the new ER concept was driven by market needs. The more compact design recognises the space limitations of point-of-use sites and compressor rooms. There is also a broader selection of models, including twin cooler versions, and optional provision for an energy savings counter. The units are designed to deliver the best possible performance at a competitive price and, depending on system conditions, a full return on investment is often achievable within 12 months.

The fully pre-assembled, plug-and-play range comprises three single cooler models: ER S1, S2 and S3 and two twin-cooler versions, ER S4 and S5, specifically designed for optimum oil pressure and flow through the unit. All of the Atlas Copco ER units’ mechanical parts are pre-mounted within the canopy to reduce commissioning time, simplify maintenance and to minimise the risk of incorrect connections.

The ER heat exchangers are now vertically configured to reduce unit footprints; compared with previous models, the single cooler version’s floor space dimensions are now reduced by 66% and those of the twin-cooler model by 33%. The units are offered with the option of complete, corrosion-free stainless steel construction, for applications where water purity is critical, or as a lower-priced stainless steel plate, copper brazed alternative, which provides a lower price alternative for non-critical water applications.

All ER units are provided with temperature sensors for ER water inlet and outlet temperature levels, these conditions can be displayed on the compressor Elektronikon controller or the ER unit energy saving counter, if fitted. Additionally, the SMARTLINK remote monitoring system allows users to continuously monitor and analyse these and other compressor conditions via an online portal. This feature allows easy creation of energy saving reports for ISO50001, ISO14001 and ESOS accreditation.

A 3m connection kit is supplied as standard while extension kits of up to 6m are available as an option. In addition, there is an energy counter module – factory-fitted or available as field sales kit – that monitors energy saving data.

New man to lead service delivery at Atlas Copco!

Mark Keen has been appointed as Business Line Manager for Atlas Copco's Compressor Technique Service (CTS) division. In his new role, Mark will lead the delivery of the company’s service proposition, which is designed to ensure customers gain the best possible performance from their air compressor systems over the long term.

Mark Keen

He said: “My mission is to develop a division that is held up as the role model for successful customer-centric organisations. I have always had a focus on developing strong customer relationships and moving from equipment sales to service has given me a fantastic opportunity to build on that. What is vital is that we gain the customer’s confidence and offer ongoing support, not just at the point of purchase but for many years afterwards to ensure our equipment continues to perform safely, reliably and efficiently.”

In his new role, Mark will also seek to raise awareness among customers of the fact that, in addition to its broad offering of service contracts and genuine spare parts, Atlas Copco Compressors’ service proposition includes a wide range of value-adding products, including AIRnet pipework, energy recovery systems, and monitoring and control products such as SmartLink and AIRScan.

More than nine years after joining Atlas Copco, he brings a wealth of experience and knowledge to his new role, leading a division that is integral to the company’s commitment to its customers. A former apprentice with a string of engineering qualifications under his belt, he joined Atlas Copco initially as a Sales Engineer in the Industrial Air division, before joining Compressor Technique Service as Sales & Marketing Manager two years ago. His promotion sees him take responsibility for a large team and he is aiming to develop those staff members to create a sustainable model for continued success.

Mark, who values optimism and enthusiasm as important personal traits, is a married father of two with a keen interest in football.

In his new role, he succeeds the former Business Line Manager for Compressor Technique Service, Sean Fairest, who, as reported last month, has been appointed as Country Manager for Atlas Copco in Ireland.

Push together piping!

Atlas Copco Compressors’ AIRnet piping system is being enhanced with the addition of the Pre Fit (PF) Series, a unique family of products that are pre-torqued for push-together assembly. The PF Series, which will be available in 20mm to 50mm sizes, does not require heavy tools and reduces installation time by up to 85 percent.

Building on the success of the existing AIRnet range, the PF Series uses the same lightweight and durable aluminium piping, together with aluminium and polymer fittings, to make installation simpler. Being five times lighter than conventional galvanised steel piping and avoiding the need to have cumbersome threading, welding and lathe machines on site for fitting, the PF Series can be installed by a single technician, reducing labour costs by as much as 20 percent.

The PF series, manufactured within Atlas Copco’s new production facility in Belgium, offers the same benefits to the end-user as the rest of the AIRnet range, being highly efficient in the way it delivers clean compressed air, as well as nitrogen gas and vacuum functions. The pipes and connections are resistant to corrosion, mechanical shocks, and thermal variations, while minimising pressure drop and leaks thanks to low-friction surfaces and seamless fittings. This ensures a longer lifespan, reduces stress upon the compressor unit itself and protects the downstream manufacturing process.

AIRnet’s low-friction surfaces and seamless fittings significantly reduce the total cost of ownership by delivering air more efficiently. For example, a 1 bar pressure drop within a piping system forces the compressor to consume 7 percent more energy.


James Houseman, Product Specialist at Atlas Copco Compressors, said: “Piping is often overlooked as a component but can have a huge influence on the efficiency, performance and lifespan of an air system. A company may have a highly efficient compressor, but its performance can be undermined without a strong system of piping. For example, a pressure drop of just one bar requires the compressor to use seven percent more energy. That’s why we urge customers to consider not just the compressor but the complete system. The new AIRnet range is designed and manufactured to remove any concerns about corrosion, leakages or loss of pressure. Yet having such an advanced solution does not mean extra work for installers; in fact, it is quite the opposite because AIRnet has unique features to speed up and simplify the installation process. There’s no need for the threading and welding machines that had to be carried around in the past. In this way, both end-users and installers can benefit from the new AIRnet range.”

Installers follow a simple five-step process to assemble the PF Series: cut; debur; mark; lubricate; and push. Once the piping is connected, there are torque indicators to provide a visible assurance of accuracy and safety.

Included in the PF series are the 40mm and 50mm diameter sizes, with the 20mm and 25mm due to have PF fittings by mid-2014. The 63mm, 80mm, 100mm and proposed 158mm sizes will retain a classic fitting.

An advantage of the AIRnet range is that the classic and PF fittings are interchangeable, while the new Adaptor Union kit allows connectivity with an existing BSP/NPT threaded system. Additionally the breadth of pressures the PF series allows has been expanded, from a minimum of 0.013 bar to 16 bar, compared with 0.13 to 13 bar in the classic range. Similarly, the temperature range has been expanded in the PF series, which means the piping can be operational from -20°C to 80°C, compared with -4°C to 70°C.

The wide scope of requirements that can be met by the PF series is further extended with the availability of an optional conductivity strip for ATEX applications in hazardous environments, which is the first of its kind in the market.

To help with design and quoting for a new system, the AIRnet support tools provide calculations of pressure drop and an automated list of required products.

The reliability of the AIRnet range is backed by a 10-year guarantee.

Data monitoring programme for compressors

Atlas Copco has launched SmartLink, a new data monitoring programme for compressors that intelligently gathers, compares and analyses data to help compressed air users increase maintenance and service efficiency. Making smart use of connectivity, data monitoring and business intelligence, Atlas Copco helps customers to get a better view of their maintenance needs, maintain production uptime and improve, wherever possible, their operating costs by minimising energy consumption.

Until now, the service of compressors and compressor rooms was either based on regularity (ie organisations with service contracts in place that ensure planned visits from a service technician) or was conducted on a reactive basis (an unforeseen problem requiring an immediate intervention). According to Atlas Copco this doesn’t need to be the case anymore: The SmartLink data monitoring program enables the monitoring of productivity on a 24/7 basis.

SmartLink provides businesses with a complete insight of their compressed air production. It helps to predict potential problems (and thus anticipate them); and shows how and where production can be optimised and energy can be saved.

There are three different options available: SmartLink Service which enables the user to easily schedule maintenance visits as they have an overview of machine data and the time left before a service is due. The service log book is always just one click away and the online link with Atlas Copco allows them to request and receive quotes for spare parts or additional services quickly.

The second option SmartLink Uptime allows the end user to be informed by email or SMS message if there is a problem with their compressed air production. Based on this information the necessary actions can be taken to avoid the risk of a breakdown. It is possible to visit the website at any time and see the actual warning/shutdown status of the machines as well as a history of previous notifications.

Finally, SmartLink Energy enables the continuous monitoring and analysis of the energy
efficiency of a compressor room. The user defines the performance indicators (such as air pressure) and the benchmarks and immediate improvements can be made when needed. The results can be used for energy monitoring according to ISO50001

Over the coming years it is Atlas Copco’s ambition to integrate SmartLink into air production installations worldwide and help customers benefit from the insight it offers.

SmartLink is an easy to install, efficient to consult, and simple to tailor data monitoring program. Data is gathered, compared, and analysed efficiently and when needed, warnings are sent out in order to prevent downtime. This data enables local service organisations to plan and prepare their interventions. As a result service efficiency increases, time is gained and money is saved.

Compressors keep pace

When Michell Instruments needed to upgrade its compressed air supply to meet expanded capacity at its factory in Ely (GB), it required a supplier capable of providing highly reliable and efficient technology. For this reason they chose to install oil-free compressor and dryer solutions from Atlas Copco.

Michell - Easidew calibration system

With over 30 years’ experience, Michell Instruments designs and manufactures a wide range of transmitters, instruments and systems capable of measuring Dew-point, humidity and oxygen in a variety of applications and industries that includes power generation, process, oil and gas and, significantly, compressed air.

Its production and calibration processes are critically dependent upon a continuous and reliable supply of quality compressed air and over the past ten years, as the company’s production and calibration facility has expanded, Atlas Copco has matched this growth and production demand with oil-free compressor solutions that offer increased capacity and technical sophistication.

As Graham Daines, Michell’s Calibration Laboratory Manager explains: “The compressed air is used to supply the Dew point calibration systems we use. These systems vary in design, but basically perform the same function of mixing varying amounts of moisture into very dry air (-100 °C Dew point) to give a range of Dew points from -100 to +90 °C. The systems perform Dew points calibrations under our UKAS accreditation and all traceable Dew point calibrations on manufactured instruments and sensors.”

The UKAS calibrations are low volume, typically less than 10 units per week, but the production calibration systems are high volume, at the rate of more than 250 units per week. As the number of systems in the production and development departments has increased over the years, and with the latest high volume systems using 100 litres of air per minute, there has been a corresponding need to increase the air supply.

The most recent addition of an Atlas Copco oil-free ZT22 compressor and two CD dryers, supplied and installed by Peterborough-based Anglian Compressors and Equipment Ltd, underlines the fact that air quality is vital to the calibration procedures. As Graham Daines confirms: “The calibration systems use pressure swing dryers to achieve the -100 °C Dew point air and require the air supplying them to be dry and oil free. We cannot risk contaminating the calibration systems or the sensors we calibrate. This is why we have never considered oil lubricated compressors with oil filtration.”

Continuity of supply is equally important, that is why the company has set up a system of compressors and dryers to ensure continuity in the unlikely event of a breakdown or when scheduled equipment servicing is required.

Previously there were two existing dryers plus three piston compressors, installed by Anglian Compressors, but this system was upgraded when the company moved from Cambridge to its new Ely factory in 2007. An Atlas Copco SF-15 scroll compressor was installed with one of the existing dryers. This enabled Michell to maintain the calibrations system in Cambridge and transfer the others one at a time to Ely, ensuring that each was fully operational at the site before moving the next one. When the move was complete, the set up comprised the SF-15 with two dryers (one for backup), with the two piston units working together as backup for the SF-15, should it be required.

The factory then underwent a substantial expansion programme during 2011 to meet global demand − a 20,000sq.ft extension that would enable the company to double its production output through additional calibration systems.

The air supply was already very close to its limit so, in July 2011, an Atlas Copco ZT-22 oil-free compressor was installed together with two CD70+ dryers (again, one for backup) with the scroll compressor and the two piston units working together as backup for the ZT machine during service periods. Anglian Compressors were able to install the ZT-22 and the Atlas Copco dryers plus all the compressed air system’s pipework without any interruption to the essential air supply.

Graham Daines commented favourably on the essential synergy between his company’s technical needs and the support of his Atlas Copco distributor: “Anglian Compressors has always appreciated the importance of our air supply and respond ASAP to any problems we have.”

Air quality

Need for high air quality to drive oil-free compressors market
By Katarzyna Owczarczyk, Research Analyst, Industrial Automation & Process Control, Frost & Sullivan

Katarzyna Owczarczyk is a Research Analyst with the Frost & Sullivan European Industrial Automation and Process Control Practice. She focuses on monitoring and analyzing emerging trends, technologies and market behavior in the Industrial Automation and Process Control industry in Europe.

Compressed air has become vital for day-to-day operations in most industries. Currently, the most commonly used compressors are oil-injected rotary screw. As the name suggests, it requires oil to operate. However, contamination of the oil by even the smallest quantities in purity-critical compressed-air applications can result in damaged products or product batches, high rejection rates and returns and costly production downtime and cleanup. In order to overcome these issues, end users are increasingly turning towards oil-free compressors.

Frost & Sullivan is of the view that the European oil-free compressors market is likely to witness tremendous growth in future. The market registered revenues of $540.0 million in 2008, and is estimated to reach $668.0 million in 2015.

Chart 1 provides the revenue comparison of oil-free compressors and industrial compressors for the European oil-free compressors market in 2008.

Chart 1 Oil-free Compressors Market: Revenue Comparison of Oil-free Compressors and Industrial Compressors (Europe), 2008Source: Frost & Sullivan

Benefits of Using Oil-free Compressors
Special thrust is given to oil-free compressors, as unlike oil-injected or technical oil-free that emit some levels of contaminated air, oil-free compressors deliver 100% oil-free air. Thus, there is no risk of oil-contaminated compressed air.

Besides, the running costs of oil-injected compressors are higher than oil-free compressors. Oil-injected compressors require regular oil filling and frequent filter changes to prevent air contamination and serious shutdown conditions. Moreover, cost is involved in consuming oil and the disposal of oil residue is an additional cost. These costs, although not apparent at the time of purchase, are very high and contribute substantially to the total cost of ownership. In comparison, the maintenance costs of oil-free compressors are very low. Oil-free compressors eliminate the need to periodically check the oil level, the need to refill oil and the need to change oil and cartridges. Consequently, the need to treat the exhausts is also nil. Moreover, oil-free compressors tend to be more energy efficient, cutting down energy costs even up to 30.0 per cent. As energy forms 70.0 per cent of the total life cycle cost of a compressor, the savings can be substantial.

Finally, oil-free compressors solve the existing problems of pollution and oil waste management caused by lubricated types of compressors. By using oil-free compressors, there is no risk to the environment due to pollution by oil leakages, there is no need to dispose exhaust oil and filter cartridges and there is no risk of desiccant contamination due to the presence of oil. In result, oil-free compressors enable compressed air users to operate with maximum environmental efficiency.

Growing Need for the Highest Air Quality
Avoiding even the slightest oil contamination is a very critical need among various end users. This is more so in critical applications, where air comes into contact with the process, such as food and beverage processing, pharmaceutical manufacturing and packaging, chemical and petrochemical processing, semiconductor and electronics manufacturing, the medical sector, automotive paint spraying and textile manufacturing.

The performance of air compressors has a direct impact on product quality and production costs and end users in all these critical applications cannot afford for any shortcomings otherwise, they stand to lose market position and reputation. Consequently, much more end users, be it big, small or medium-sized, are investing in oil-free air compressors, which guarantee premium air quality, eliminating any concerns of product safety.

Food and beverage, life sciences and others, including automotive, chemicals, oil and gas, pulp and paper and other niche applications, held the largest share in the European oil-free compressors market in 2008. Shares of these end users are expected to rise from 2008 to 2015, except others which have been affected by the economic recession. The power generation industry is also expected to grow during the forecast period. However, due to the impact of the economic recession, the electronics industry is expected to be severely affected until 2010. The textile market is expected to decline in terms of revenue share, because of the growing trend of moving textile production to low-cost labour countries in the Middle East and Asia.

Conclusion
The European oil-free compressors market is expected to grow steadily from 2010 onwards, driven by the demand from food and beverage, life science and electronics industries, where high air quality is very important. Most of these critical applications have already implemented oil-free compressors on taking into account the benefits of using such compressors. Moreover, given the current economic situation, it is not profitable to use unreliable and costly lubricated compressors in most of these applications. In future, other applications are expected to follow suit. The European oil-free compressors market is estimated to generate $668.0 million by 2015, growing at a compound annual growth rate (CAGR) of 3.0–4.0 per cent from 2008 to 2015.