Scales Industrial Technologies Exceeds Expectations and Helps Improve Production and Save Energy.
Faced with rising energy costs, Summit Corporation
of America sought to improve the efficiency and
reliability of its compressed air system. After getting a
quote from their vendor on a new 300-hp compressor
to replace an existing unit, the company sought a
comparison quote due to the significant investment the
new compressor represented. Based on a
recommendation from one of their customers, Summit
turned to Scales Industrial Technologies. Rather than
simply providing a quote for a new compressor,
Scales recommended a compressed air system
assessment. This impressed Summit's president, Harry
ScobIe, who gave Scales the green light to assess the
system. Scales' engineers found that by modifying
some production equipment, Summit could reduce its
compressed air demand by 80%. This would allow the
company to operate just as effectively with a much
smaller compressor and achieve significant energy
and maintenance savings.
Founded in 1948, Summit Corporation of America is one of
the largest independent electroplaters in the United States,
for continuous reel-to-reel and rack and barrel processes. Located in
Thomaston, Connecticut, Summit has almost 100 employees and a customer base of over 500 companies within the automotive, commercial, aerospace, and
electronics markets.
The Project:
The primary demand for compressed air in Summit's plant
was from a series of compressed air-driven nozzles that
atomized water to rinse away chemicals used during the
plating process. Working with a nozzle manufacturer,
Scales designed a process change that enabled the strip
washing nozzles to use only water instead of compressed
air. Eliminating the air-driven strip washing sharply reduced
the plant's compressed air requirements.
The assessment found that a filter press was being fed
an unneeded, constant supply of compressed air. Scales
engineers' worked with Summit employees to
install high pressure off-line air storage
supplied by a 5-hp reciprocating compressor
to accommodate the high volume, intermittent
demand of the filter press. This further
reduced the load on the main compressor.
Finally, a leak detection and repair campaign
led to additional compressed air energy
savings. The combination of all these
measures reduced the plant 's air demand to
where it could be met with a smaller
compressor. Summit was able to replace their
300-hp compressor with a 75-hp variable
displacement compressor and a new, energy
efficient dryer.
Results:
Not only did Scales' recommended project improve energy efficiency and yield significant energy saving, it also improved production and yielded important non-energy benefits. Compressed air energy use was reduced by more than 80%, saving 1,631,000 kWh and $153,000 per year. The project also resulted in annual savings of $49,000 from lower water and water treatment costs, lower cooling tower loads, and lower maintenance costs. In addition,
production became more reliable, leading to $50,000 in annual avoided product loss. Because
Summit qualified for an incentive of $217,500 from its electric utility, Connecticut Light &
Power, total implementation costs were $72,500, resulting in a simple payback of just over 4
months. This project's success has encouraged Summit to become more proactive about energy
efficiency.
Summit President Harry Scoble: "They recommended a system assessment rather than just providing a quote for a new compressor...that got my attention."
Ron Gross, VP Engineering Summit Corporation: "Scales worked with our operators to retrofit our rinse lines utilizing state-of-the-art technology. Involving our operators in this retrofit process was key to gaining their commitment and enthusiasm. In addition to the anticipated energy savings, we are enjoying a higher quality surface finish along with enhanced process consistency and capability."
Founded in 1966, Scales Industrial Technologies is a leader in compressed air system design, helping commercial and industrial customers improve energy efficiency throughout the U.S. and internationally. Their expertise encompasses a full range of commercial air products including air treatment, cooling, process chilling, and more. Scales Industrial Technologies offers state-of-the-art compressed air system analysis, evaluation and engineering design and production solutions. Scales Industrial Technologies is also a longstanding U.S. Department of Energy (DOE) Allied Partner and a founding member of the Compressed Air Challenge (CAC). The company's president and founder, Bill Scales, co-authored the CAC's Best Practices Manual for Compressed Air Systems and is on the CAC's Core Technical Committee. In addition, five Scales employees are CAC certified instructors.
For more information on how Scales Industrial Technologies can help your company save energy and money, visit our website at www.scalesindtech.com, email at info@scalesair.com or call:
Wooster, MA 877-798-0454
Meriden, CT 800-627-9578
Carle Place, NY 866-248-9096
West Paterson, NJ 866-890-1010
Sharon Hill, PA 866-522-8480
