Auditing the energy efficiency of compressors

CHEP, a provider of pallet and container pooling solutions, has achieved significant energy savings through the installation of energy-efficient Atlas Copco compressors at its pallet production and repair sites in the UK. The savings from the installation have been measured at over 1000 tonnes of CO₂ emissions.

CHEP has a network of service centre facilities located across the UK where pallets are returned, inspected and repaired before being reissued into the supply chain. Seven of these plants have installed Atlas Copco equipment, including 8-9 bar compressed air which is used to transport the wooden pallets around the inspection and repair process. There are also two air-driven nail guns on each repair bench and an average of 20 benches at each site. Together, these installations have helped to optimise the compressed air system used in all sites, as well as eliminate air leaks.

As a sustainable and environmentally aware organisation, CHEP is committed to minimise its energy demand and carbon footprint. Subsequently, the company’s UK site managers undertook an 18-month review of energy efficiency and CO₂ emissions at the company’s process plants. The project included the monitoring and assessment of compressor system efficiency at the seven service centre sites.

As part of this energy consumption and performance audit, Atlas Copco’s Manchester-based distributor, Compressor Engineering, installed iiTrak datalogger units for a specific period at each compressor installation. From this data, the conclusion was reached that by installing more energy-efficient compressors, backed by a program of planned, preventative maintenance, optimum performance could be achieved, along with reduced energy costs and increased carbon savings.

At the end of 2011, CHEP installed a number of Atlas Copco GA-series rotary screw compressors at five of its sites and transferred other existing units between the company’s remaining two sites. All of the Atlas Copco machines installed featured variable speed drive (VSD) technology that matches compressor output to fluctuating demand - with the potential to realise consequent energy savings in the region of 35%. CHEP also chose to support the new VSD compressors and the existing machines with an Atlas Copco Comfort Air service and maintenance package handled by Compressor Engineering.