Case study · Energy efficiency
Upgrading Packaging Efficiency with Variable Speed Compressors
A customer recently expanded their manufacturing facility with new packaging lines and required a reliable, efficient compressed air system to support the upgrade.
They needed a robust solution capable of handling fluctuating production demands without causing unexpected downtime or inflating their utility bills.
£4,000/yr
estimated energy savings
£6,000
extra VSD investment
The challenge
The Challenge: Balancing Upfront Costs and Long-Term Efficiency
When quoting for the project, we provided the client with two distinct pathways: a standard fixed-speed compressor and an advanced Atlas Copco Variable Speed Drive (VSDs) system.
While the fixed-speed option was approximately £6,000 cheaper in upfront costs, it would run continuously at full capacity regardless of actual air demand, leading to significant energy waste.
The challenge was demonstrating that the cheaper initial purchase would ultimately be the more expensive choice over the equipment’s lifecycle.
The solution
The Solution: A Fully Integrated Atlas Copco System
The client opted for the high-efficiency route. We supplied and fully installed a comprehensive turnkey system tailored specifically to their new packaging environment:
Atlas Copco GA22VSDs Compressor
The energy-efficient heart of the operation, matching its motor speed to the exact air demand of the plant and scaling seamlessly with production shifts.
UD Two-in-One Filter
Delivering superior air purity by combining two filtration grades into a single housing, which significantly reduces pressure drops.
FX Refrigerant Dryer
Reliably removing moisture from the system to protect sensitive pneumatic cylinders on the packaging lines.
OSC Oil-Water Separator & Galvanised Dry Air Receiver
Providing stable, moisture-free air storage while ensuring all condensate is treated safely to comply with environmental disposal regulations.
The results
The Results: £4,000 Annual Savings and Rapid ROI
By utilising the highly efficient VSD compressor, we estimate the client’s energy cost savings to be in the region of £4,000 per year.
Because of these massive efficiency gains, the £6,000 extra investment for the VSD model over the fixed-speed alternative provides a very quick return on investment. The technology transforms a slightly higher capital expense into a long-term operational advantage, adding direct value to the client’s bottom line from day one.
The Design Air standard
The Design Air Standard
Partnering with Design Air ensures you receive transparent, data-driven advice that looks beyond the initial purchase price. We believe in presenting all the facts so our clients can make the most profitable, efficient decisions for their specific operations.
Looking for advice on purchasing a new compressor? Get in touch with Design Air today. Our experts are happy to evaluate your usage and provide tailored options to suit all budgets.