Energy savings at a sauce manufacturer

Discover how the VPVision energy monitoring system and 3 instruments enabled significant energy savings by allowing 1 of the 2 compressors to switch from running to back-up mode.

Sauce manufacturer’s compressed air system set-up

A sauce manufacturer in the Netherlands had one central compressor room with 2 x 75 kW compressors powering their compressed air system. The system was originally designed as a 2 x 100% setup—meaning only one compressor would run at a time for production, while the other served as a backup (used in alternating shifts). However, in practice, both compressors were running simultaneously for production.

When they approached VPInstruments, they had no compressed air measurement or monitoring system in place and no idea where to start optimizing their compressed air usage.

Based on their P&ID, we recommended installing measurement devices and a permanent monitoring system. With this equipment, the sauce manufacturer was able to track leakage rates, monitor energy usage and costs, and receive alerts when the backup compressor switched on. VPInstruments’ distributor installed the compressed air monitoring equipment on site and supported the client further with an air audit and leakage survey.

Measurement & Monitoring set up:

  • 2 x Amp meters

To measure compressor consumption, to know when the compressors are turned on, off or in standby.

  • 1 x VPFlowScope flow meter

In the main header to measure flow, pressure, temperature and total flow.

  • 1 x VPVision monitoring system

To collect all data, visualize it in easy overviews and in automated reports.

 

Investment: 6000 Euros

Screenshots VPVision before improvements:

Both compressors are running

VPFlowScope output: Flow profile and pressure at the main header

Results:

We took just one week of data and calculated the leakage level during the weekend, when there was no production. This showed a leak load of 40,000 Euros/year. By further help of our distributor and based upon their audit and leakage survey, the customer could go back to their original 2 x 100% setup; one compressor could be turned off to function as back-up again.

ROI was < 2 month

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