Nitrogen in the Food Packaging Industry

Nitrogen gas is an extremely safe gas that has been used in the food packaging industry for many years. Nitrogen gas helps preserve freshness, integrity and quality of delivered food products.

It provides a pressurised atmosphere that prevents package collapse to ensure that delicate foods won’t get crushed in their bags. Nitrogen will be used in pretty much all food packaging, keeping food like crisps and nuts from getting crushed.

Nitrogen also plays a vital role in keeping food fresh and vastly extends shelf life. Nitrogen gas is clean, dry and inert. By adding nitrogen gas, oxygen is removed. Oxygen deteriorates food items due to oxidative rancidity moisture loss or gain. Purging packaging of oxygen is what allows us to have long life food on our shelves, but is also useful to keep fresh food produce fresher for longer.

Having an on-site nitrogen generator replaces the traditional cylinder and bulk-liquid supplies allowing manufacturers to generate their own nitrogen onsite easily. Clearly producing nitrogen gas onsite means you will no longer incur cylinder delivery costs.  Producing nitrogen gas onsite saves a lot of money providing a quick return on the investment made in nitrogen generating equipment. The cost of a nitrogen generator during its lifecycle is just 20 – 40% compared to the cost of buying nitrogen cylinders during the same period. Another advantage of producing nitrogen onsite is that the volume and purity of the nitrogen gas produced is entirely controlled by the user themselves according to their specific needs.

Nitrogen gas is useful not just for the food industry but also in countless other industries. Due to the diversity and cost effectiveness, nitrogen is becoming increasingly popular in a broad spectrum of industry and research laboratories. Nitrogen can be used in a range of applications such as creating inert atmosphere, as a carrier gas, blanketing, packing, purging, filling and plastic moulding.

Based in the North West, Glaston Compressor Services Ltd has vast experience in designing, installing and servicing nitrogen generators for manufacturers across the UK. Recent installations include: heavy manufacturing including treatment of metals, chemical industry where nitrogen has been used as an inert gas, food industry and the laser cutting industry. To read a case study of a Nitrogen generator installation that Glaston made at a food packaging client click here.

Glaston’s nitrogen generating equipment is space saving and modular in design which is important as it means that no expensive civil engineering works will be required. In many installations where space is unavailable for new machinery Glaston has created nitrogen generating systems within standard shipping containers that can remain outdoors.

Using the latest state of the art thermal mass flow meters and logging equipment Glaston’s machinery can accurately determine the nitrogen flow that is best suited to its client’s specific requirements. Glaston also provides bespoke service packages and maintenance contracts.

Maintenance is critical to keep a nitrogen generator running smoothly and to ensure consistent reliable performance.  Keeping a nitrogen generator in compliance with British Food Retail standards is achieved by regularly servicing and maintaining your equipment. This will include checking the overall operation to ensure efficiency, re-calibrating the nitrogen sensor, overhauling the inlet and outlet valves and changing the inlet filters that protect the nitrogen generator. Glaston recommends maintenance every 6 months.

To discuss whether a nitrogen generator is right for your business speak to one of Glaston’s experienced engineers today http://www.glaston.com/contact-glaston/.

Glaston Nitrogen

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Location, Location, Location: How Performance is impacted by the Placement of Compressed Air Equipment

The real estate mantra: ‘location, location, location’ rings true not just for real estate but also when installing an air compressor system. You may not think that the position of your air compressor is critical but actually positioning your air compressor equipment well can save energy and money, and influence the performance of your machine. In order to ensure the most reliable and efficient compressed air production and performance it is advisable to take the following into consideration – compressor location, ventilation, equipment clearance and the overall compressor room environment.

After completing many hours of research, numerous performance comparisons and established a life cycle cost analysis, you may now think you are more than ready to get the purchase requisition signed off. But many get blindsided by the number crunching and overlook the significance of the compressor room location?

Sufficient Ventilation

Air compressor and compressed air equipment requires a constant supply of cool inlet air to function well. Cool air ensures the equipment stays below its maximum operating temperature to avoid any damage to the equipment.

Poor ventilation can cause a lot of damage:

  • Lubrication degradation
  • Drive motor damage
  • Equipment shutdown
  • Excess moisture in the compressed air

Excessive moisture can overrun air treatment components. This can carry over into the plant air, contaminate end processes and lead to higher scrap rates and waste.

The process of compressing air generates a lot of heat. Another way to divert hot air from the compressor is to recover the heat generated.  This can reduce room temperature and also save a lot of money.

Clearance around Compressed Air Equipment

When laying out a compressor room it is crucial to leave ample space around the equipment. That means keeping machinery away from walls, doors and other pieces of equipment. Manufacturers will state the minimum clearance required in their service manuals and space requirements can be requested during the specification process.  Additionally it is important to ensure that sufficient space is left for a service technician to be able to service the compressor. An air compressor technician will need enough space not only to open the service doors fully but also safely manoeuvre equipment such as cranes and forklifts to be able to exchange large parts such as an airend of a drive motor.

It is also important to consider where the compressor room is to be located. It is not advisable to locate the compressor room next to the boiler room as of course this will increase the overall air compressor temperature.

Another factor that must be assessed is the air quality you have in and around your compressor room. You do not want your compressor to ingest fumes or other contaminants.

In summary location, location, location in the context of air compressors should consider ventilation, maintenance access and proximity to unwanted contaminants.

North West based air compressor supplier Glaston Compressor Services Ltd designs, installs and maintains air compressors and nitrogen generators around the UK and beyond. Glaston is an authorised UK distributor of the world famous yellow housed HPC KAESER air compressors.

For more information about air compressor system design layouts or any other compressor related issue visit www.glaston.com.

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The Flexibility of an Air Compressor

The Low Down on Hiring an Air Compressor and the advantages of Portable Air Compressors 

Hiring an Air Compressor

Hiring an air compressor can be a smart and cost-effective decision. An air compressor is a big investment and a decision to buy one should be an informed choice. If you are not certain of your compressed air requirements then hiring one is a good way to test the water before making the decision to buy. Hiring an air compressor is also useful to those who need a temporary replacement or if additional machinery is required to suit an immediate need. Hiring an air compressor can be an effective way to utilise compressed air for a single task or job or to cope with an unexpected influx in demand.

Ultimately the decision to rent or buy an air compressor comes down to finance and demand. Renting a compressed air system will mean that you know exactly what you need to pay with no unexpected maintenance costs.  Depending on the intended use, you could save money in comparison to buying an air compressor that may be sparsely used. Hiring an air compressor can be very cost efficient as you only borrow the compressor on an ‘as-needed’ basis.

Glaston Compressor Services Ltd based in the North West hires out a range of different air compressors offering a delivery and fitting service. You can hire an air compressor from Glaston on a weekly, monthly or rent-to-own basis. Glaston offers flexible, cost-effective rentals with scheduling designed to make it more convenient for its customers. Glaston also offers leasing packages for air compressors and other machinery.

Glaston stocks a range of air compressors from HPC KAESER available to hire. Glaston is an authorised distributor of HPC KAESER Compressors in the UK and supplies static electrical and portable diesel driven compressor equipment suitable for any application. Compressors available for lease or hire are available in both oil free and oil flooded options.  To find out more about Glaston’s Air Compressor Hire Service visit: http://www.glaston.com/air-compressor-services/air-compressor-hire/

Portable Air Compressors

The use of portable air compressors has risen significantly in recent times mainly due to the increase in construction which requires the use of portable air compressors onsite.

Portable air compressors function in the same way as a standard air compressor. The main advantage of a portable air compressor is obvious, it is portable and therefore can be moved between job to job or from location to location within the factory or on site. A portable compressor has wheels to roll the compressor around the site and is therefore much more lightweight than its full-sized counterpart.

HPC KAESER has developed a series of portable air compressors which are far less noisy than a full-sized compressor. It is a myth that portable air compressors are less powerful than standalone compressors with many portable air compressors designed for rugged use and dependable performance.

The HPC KAESER Mobilair portable compressor is designed to give you air wherever you need it with a fuel-saving motor and heavy-duty chassis that features a rotational moulded PE enclosure that is tension-free for extreme dent resistance. Glaston supplies a range of different portable air compressors to choose from and would be happy to discuss which portable compressor would be most suited to your specific needs.

To find out more about all of Glaston’s compressor services contact us here or call on 01695 51010.

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What a Compressed Air System Audit can do for your Business

Compressed air is a very versatile tool used in a broad range of industries to power machinery, valves and actuators and hand tools.  Compressed air generation accounts for 10% of all energy consumed in UK.  The Carbon Trust has reported that the UK uses over 10TWh of electricity annually to compress air which is the equivalent of about 1.5 power stations emitting 5 million tonnes of CO₂ to the atmosphere or powering 120 million 60w (equivalent) LED lightbulbs for a year.

However the process of compressing air can be very wasteful. As little as 8% of the total energy supplied to a compressor is actually converted into useful energy at the point of use.

Effective minimisation of waste can save over 30% of the energy required. Small leaks in a compressed air system can waste huge amounts of energy; a leak as small as 3mm could cost more than £700 a year in wasted energy.

Conducting a compressed air system audit is vital as it is the easiest and most thorough method to ensure that your compressed air system is performing to its upmost efficiency. There are several legal requirements when using compressed air such as having the system regularly checked by a competent engineer.

Using a reliable compressed air maintenance team who will come to your plant and examine your compressed air system can be really beneficial. The compressor engineer will produce a checklist of suggested improvements to your compressed air system. The most common issues that a compressed air system audit will flag up are leaks, unfit piping, inefficient compressors and the need for an air compressor controller.

A compressed air system audit generally more than pays for itself in the energy savings made within a relatively short time. However optimising individual components in a compressed air system does not necessarily result in optimisation of the entire system. For a more effective result it is better to take a systematic approach by analysing each component of the compressed air system.

A compressed air system audit looks to maximise uptime and reduce total operating costs. The audit will measure the actual compressed air demand at various times to produce an Air Demand Analysis (ADA).

The world famous air compressor brand HPC KAESER has a specialised energy saving system software which makes specific recommendations regarding the most suitable machine configuration. An average audit saves around 30% of energy use and often much more.

Once the information has been collected and analysed the audit will produce a personalised action plan with the best solution for the minimisation of energy consumption and maximising uptime for the recommended machine configuration.

North West based Glaston Compressor Services Ltd is a HPC KAESER UK authorised distributor. Glaston has been operating for nearly 40 years and offers the full package in compressed air maintenance, compressed air treatment and other compressed air services. Glaston also supplies nitrogen generators, air compressor hire and used air compressors.

Glaston has secured its status as a leading compressed air service provider in the UK due to its strong customer service based approach and its expertise. Glaston has saved many businesses across the North West thousands of pounds by designing, installing and maintaining efficient air compressor systems.

For more information about HPC KAESER products or any air compressor related issues or to book in for a compressed air system audit contact us here

or call on 01695 51010.

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Why you DO need a portable Air Compressor….

An air compressor is a machine that is relied upon heavily across countless industries. A portable air compressor gives business considerable benefits around their factories and plants. The ability to move the air compressor from one location to another with minimal effort is clearly its leading benefit. The smaller size and lighter weight of portable air compressors mean they have a much more flexible use. Their small and compact size makes storage space required minimal. Portable air compressors are also much quieter than their stationary air compressor counterparts.

When thinking portable air compressors, the brand that comes to mind is the worldwide industry leaders HPC KAESER Compressors. HPC KAESER has a range of portable air compressors called the MOBILAIR. These compressors are compact powerhouses with petrol engines of up to 15 bar pressure. Even the smallest HPC KAESER MOBILAIR portable compressor is more than capable of powering breakers, drills, saws, grinders, impact wrenches and impact borers. The compressor can even be equipped with an external compressed air aftercooler for applications that require cool and condensate-free compressed air.

It is useful to know in our chilly British winters that the HPC KAESER compressors are built to withstand freezing temperatures with their patented anti-frost control. This mean that the portable compressor models can be relied upon with flow rates from 2-5.6 m³/min. Combined with a tool lubricator you can be sure that your tools will also not freeze and also extend the air tool service life and availability.

HPC KAESER has developed a SIGMA CONTROL MOBILE designed to boost free air delivery up to 34 m³/min. The innovative compressor control is simple to use and precisely matches motor power to actual compressed air demand significantly enhancing compressed air availability and fuel efficiency.

KPC KAESER has even developed an emission free portable compressor: the HPC KASER e-power. The e-power is the alternative, emissions-free drive for portable compressors useful when there is an electrical power available. The e-power is very quiet compared to its diesel counterparts making it useful for noise protection zones. Its emission free characteristic makes it ideal for use in tunnels, buildings and low emission zones.

North West based Glaston Compressor Services Ltd offers a wide range of static electrical and portable diesel driven compressor equipment suitable for any application. Glaston offers air compressor hire packages which are available in oil free as well as oil flooded options. Glaston also stocks a full range of ancillary equipment that is available to hire, including desiccant dryers, fridge dryers and filtration for any specification.

As well as hire packages Glaston also has a wide range of used air compressors that are available for resale.  Glaston is an authorised UK distributor of HPC KAESER air compressors.

For more information about the HPC KAESER MOBILAIR compressor range or any other portable air compressor visit www.glaston.com .

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The Benefits of Nitrogen Generation for the Pharmaceutical Industry

Nitrogen gas is the sister function of compressed air. Nitrogen gas is needed by most industries for a diverse number of uses. Generating nitrogen gas onsite is another way for businesses to make cost savings as well as other efficiencies. Moving from delivered liquid nitrogen brings your business many benefits.

Before deciding on any company investment there are a few questions you will likely ask yourself.

  • Will a new nitrogen installation make a safer working environment for employees?
  • Would a new nitrogen generator installation make us more eco-friendly?
  • Will the energy savings made allow me to have a quick return on the investment made?
  • Will producing nitrogen onsite make long-term savings?

When the answer to all these questions is YES, it is difficult to understand why every manufacturer does not invest in a nitrogen generator in their plant. But in recent times more and more manufacturers who rely on nitrogen gas are taking the leap forward to producing their own nitrogen on site leaving behind the antiquated method of receiving delivered liquid nitrogen. The nitrogen generation equipment is expected to pay for itself within 5 years. Considering plant space costs considerable amounts of money, not needing to store liquid nitrogen onsite is also an added bonus. And of course with savings as large as 40 to 80% based on current liquid nitrogen prices making the leap is becoming more of a no brainer.

Medical and Pharmaceutical uses for Nitrogen Gas

Nitrogen gas is essential in the pharmaceutical industry, from packaging to fire suppression in an obviously volatile environment. Nitrogen gas is used to keep products dry and sterile to improve their durability. Nitrogen gas is also used to reduce the amount of oxygen in situations where combustion is a serious concern. Previous nitrogen generators did not give a sufficient purity required for pharmaceutical use.  However with the latest technological advancements in nitrogen generation, nitrogen generation is producing purities equal to liquid nitrogen. This is good news for the pharmaceutical manufacturers reducing their production costs without compromising on quality or efficiency. Nitrogen generators are safer and easier to handle than high pressure cylinders.

It is interesting to note that nitrogen is only turned into liquid form for safe transport. It actually takes a considerable amount of energy to convert it from gas to liquid and then back to gas form for use.  Therefore producing nitrogen gas onsite is not only a cost saving win but also helps to reduce your carbon footprint.

Glaston Compressor Services Ltd has expertise in the design, supply and maintenance of nitrogen generators across the whole of the UK. Glaston’s team of highly qualified service engineers provides services not just for nitrogen generators but also for air compressors and compressed air filters. Glaston Compressor Services supplies, installs and maintains a range of industry leading brands. Glaston is an authorised distributor of the world renowned HPC KAESER Compressors. Glaston has built up a strong loyal customer base due to its ongoing dedication to quality and customer service.

For more information about the savings you could make with a nitrogen generator speak to a member of the Glaston team – visit www.glaston.com for more information.

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Love is in the Air: How to Love your Air Compressor

Your air compressor is probably the most important piece of equipment in your business. Being at the heart of your operations your air compressor is pumping the ‘blood’ to all the vital ‘organs’ around your plant to ensure everything is working. Your air compressor is your trusty workhorse quietly getting on with its work with minimal fuss and dependable reliability.

So with Valentine’s Day upon us it is time to give your air compressor some attention. Just like any piece of equipment there are times when you need to assess the current and future needs of your business and make important decisions.

When the time comes to retire your old workhorse air compressor, don’t make the mistake of replacing it like for like. Using old technology would be a mistake. It may seem rather daunting researching new compressor technologies with scary looking price tags and complex technical specifications. Don’t be intimidated by the homework or blindsided by the facts. By contacting a reputable air compressor supplier you will receive informed and professional advice so you will be able to assess your air compressor and make clear and informed decisions about the current and future compressed air needs of your business.

When choosing a new air compressor it may be tempting to go for cheaper options that claim to achieve similar results. But as with most things in life choosing a branded option is almost without a doubt going to perform better than a cheaper version: as the expression goes ‘buy cheap, buy twice’.

HPC KAESER Compressors have been relied upon by customers across the globe for nearly 100 years and are an infamous feature in most factories in the world recognised by their bright yellow casings. Glaston Compressor Services Ltd is a HPC KAESER Compressor UK authorised distributor. Glaston Compressor Services provides professional and experienced customer support and service to all buyers of HPC KAESER Compressors within the UK.

To have your air compressor assessed or to discuss your compressed air needs contact Glaston today for personal and professional advice. Visit www.glaston.comfor more information.

Your air compressor is probably the most important piece of equipment in your business. Being at the heart of your operations your air compressor is pumping the ‘blood’ to all the vital ‘organs’ around your plant to ensure everything is working. Your air compressor is your trusty workhorse quietly getting on with its work with minimal fuss and dependable reliability.

So with Valentine’s Day upon us it is time to give your air compressor some attention. Just like any piece of equipment there are times when you need to assess the current and future needs of your business and make important decisions.

When the time comes to retire your old workhorse air compressor, don’t make the mistake of replacing it like for like. Using old technology would be a mistake. It may seem rather daunting researching new compressor technologies with scary looking price tags and complex technical specifications. Don’t be intimidated by the homework or blindsided by the facts. By contacting a reputable air compressor supplier you will receive informed and professional advice so you will be able to assess your air compressor and make clear and informed decisions about the current and future compressed air needs of your business.

When choosing a new air compressor it may be tempting to go for cheaper options that claim to achieve similar results. But as with most things in life choosing a branded option is almost without a doubt going to perform better than a cheaper version: as the expression goes ‘buy cheap, buy twice’.

HPC KAESER Compressors have been relied upon by customers across the globe for nearly 100 years and are an infamous feature in most factories in the world recognised by their bright yellow casings. Glaston Compressor Services Ltd is a HPC KAESER Compressor UK authorised distributor. Glaston Compressor Services provides professional and experienced customer support and service to all buyers of HPC KAESER Compressors within the UK.

To have your air compressor assessed or to discuss your compressed air needs contact Glaston today for personal and professional advice. Visit www.glaston.com for more information.

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2017’s New Year’s Resolution: 5 Air Compressor Energy Saving Tips

January is an ideal time to reflect on the progress and achievements of 2016 and to make plans for the months ahead.  We welcome a fresh new start after a hard year on business, following the shock Brexit result and its effects on the British economy. We witnessed our Prime Minister David Cameron resign and saw Theresa May elected into power. May then went on to appoint an entirely new cabinet. All this upheaval affected the markets. The pound was negatively impacted and it will still take some time to recover to its pre-Brexit value.  The on-going economic and political uncertainty will inevitably create a more risky competitive global environment for manufacturers to operate within.  But as well as these apparent challenges, each year brings with it real opportunities to achieve new heights of operational improvement.

So starting the New Year with a New Year’s resolution couldn’t be a better idea. So what is a good way to improve your bottom line and increase profit? Saving energy is a relatively easy way to ensure money made stays in your pocket.

Energy prices change frequently reflecting expectations of supply meeting demand. Since March 2016 wholesale electricity prices have risen 35% and wholesale gas has risen 36% which is expected to add a 5% increase on energy prices for homes and businesses in 2017. But surprisingly despite an increase in energy costs, it is still possible to save money in business.

We’ve come up with some simple tips designed to help improve your manufacturing efficiency which can be acted upon immediately.

If your business is using compressed air, it is most probable that this makes up the largest portion of your energy consumption cost. With minor tweaks, reductions of up to 15% can be made. Here are our 5 tips to making sure your air compressor is working to its ultimate efficiency.

Tip 1

Maintenance

This is something that you should already be doing religiously regardless. Replacing filters and oil on your air compressors allows the air compressor to work as efficiently as possible. Changing the elements in in-line filters will reduce pressure drops. Keeping the dryer condenser coils clean allow the compressor to work efficiently. Keeping the coils on the compressor cool will stop the compressor overheating- again saving energy. Ensuring a proper preventative maintenance program is essential. Using a reputable compressor company to draw up an effective maintenance program is a wise idea, not only to save energy but also to help prevent break downs and lost production with machinery downtime.

Tip 2

Fix Leaks

If you think about an air conditioning system; when you have the air conditioning on you would not leave the window open. The same applies to your air compressor system. Having a leak in the system is the same principle as leaving the windows and doors open when the air conditioning is working. Hundreds of pounds of electricity are literally lost. Your compressor must work harder thus increasing maintenance and wear and tear on the compressor.

Tip 3

Lower the Pressure

Reducing the system pressure by 2 psi saves 1% on your energy bills. Any leaks in the system will leak less air at lower pressures. It is recommended to reduce system pressure to just above what you use. Having a good storage tank and an air system with a low-pressure drop means you are able to reduce the system pressure immediately. Not having adequate storage is foolish as it saves money in numerous ways.

Tip 4

Pressure Drop

The pressure drop is the difference in psi between the compressor air outlet to the point of use. This can be caused by having a pipe that is too small, or in-line filter elements not being changed or having too many twists and turns in the pipe. Keeping filters clean is an easy fix. The other changes need consideration by an expert as they can be quite costly and would need to ensure than the return on investment is high enough to justify the expense.

Tip 5

Reduce blow down

It is often seen that employees use the compressed air to clean by taking a hose and blowing the dust off the machinery. By using an open hose a considerable amount of money is lost each time. This is essentially just a leak thus reducing the pressure and size of the leak will save a lot of money. The way to do this is to invest a minimal amount in a regulator and a blow gun which will not cost more than a couple of hundred pounds but will save you hundreds of pounds in energy costs. Using the smallest possible vent blow with the minimum possible pressure required will still do the dusting down job and save hundreds at the same time.

How we can help?

Glaston Compressor Services Ltd is a leading UK supplier working across the UK designing, installing and maintaining air compressor systems. Glaston has secured their status as market leaders due to their team of highly qualified and experienced service engineers and excel in air compressor maintenance.  Glaston specialises in providing energy saving solutions to their clients.

Glaston is an authorised distributor of the world-famous air compressor brand- HPC KAESER Compressors. KAESER compressors are recognised by their distinctive yellow boxed compressors and dominate the market due to their reliability and energy efficiency.

Glaston also offers additional compressed air services such as air compressor hire, compressed air dryers, compressed air treatment and compressed air filtration.

For more information on how your air compressor can save energy in your business contact Glaston, or visit www.glaston.com

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It’s beginning to look a lot like Christmas…..

Glaston’s top 5 tips to protect your compressor during the Festive Season!

Is your factory closing down over the Christmas and New Year break? This is often the only time of the year that many factories stop production completely and shut up shop.

Unfortunately, this time period co-incides with some of the coldest weather of the year as we are already experiencing.  Many industrial compressors have run all year at +70 degC, so when they are shut down and cool to close to freezing this can give rise to condensation problems with the electrics and motors.

At Glaston, we offer bespoke maintenance advice to help shutdown your cooling water system, or air compressors in the correct manner ensuring they are reliable on restart. The main points to consider are as follows:

  • Make sure you shut the compressor down in accordance with the instruction book for the particular piece of equipment. This will ensure that the unit is stopped in the correct manner – don’t be tempted to shutdown using the emergency stop unless there is an actual emergency. Emergency stopping causes the compressor to stop whichever mode it is in and this isn’t good practice as it causes undue stress. By stopping via the emergency stop also means that you / or another have to reset it when starting up again. 
  • If possible block any vents into the compressor room to help keep the compressor room above +5 DegC – if you have risk of the room falling below zero then we would strongly recommend additional room heating for frost protection. 
  • If you are operating water cooled compressors make sure your water is correctly treated with antifreeze. If not and the temperature drops, as with any water supply, it will cause damage to the compressor and the cooling water system itself which isn’t easily repaired and can be very costly.
  • Drain all air receivers to make sure there is no condensate left to sit and freeze in cold weather. 
  • When re-starting a compressor after the break, release the air to the factory slowly and in a controlled manner as rapidly refilling the system could damage your system, the compressor and its ancillary equipment.

So don’t get your tinsel in a tangle this Christmas! Contact Glaston now and be prepared. We can answer your questions or offer specific advice.

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The Main Types of Compressed Air Dryers

There are 4 main types of compressed air dryers: refrigerated compressed air dryers, chemical compressed air dryers, desiccant compressed air dryers and membrane compressed air dryers.

 

Refrigerated Compressed Air Dryers

Refrigerated compressed air dryers cool the air to low temperatures and condenses the water vapour. With a refrigerated compressed air dryers, it is not possible to realise dew points below freezing, a modern refrigerated compressed air dryer can produce air with dew points as low as 2 °C. As some water vapour is left in the air a refrigerated dryer is not suitable in a water vapour sensitive applications such as pharmaceutical and electronic manufacturing.

 

Desiccant Compressed Air Dryers

There are two types of desiccant compressed air dryers: heated and heatless.

Desiccant compressed air dryers pass the compressed air over a bed of desiccant material which absorbs the water vapour. When the bed capacity is nearly saturated the air flow is moved to another bed of desiccant material whilst the first bed is regenerated. Heated desiccant dryers use heat to remove water vapour from the desiccant material which requires a large amount of steam or electricity; whereas heatless dyers use the dry air generated by the dryer to remove the water vapour. To regulate the regeneration timers and minimise energy usage dewpoint monitors are used. These dryers are most common for high quality air applications with very low air vapour requirements. They are also suitable for compressed air is subject to freezing conditions as the dewpoints go as low as -70°C.

Membrane Compressed Air Dryers

Membrane Compressed Air Dryers utilise specially formulated membrane microtubes that are selectively preamble to water vapour: as the compressed air travels along the membrane the water vapour passes through the membrane leaving dry compressed air. A small stream of dry compressed air is pushed along the outside surface of the membrane to move away the moisture laden air. A membrane compressed air dryer can operate as low as -40°C and they are favoured as they have no moving parts, require very little maintenance, and operate with minimal noise output. They are even explosion proof so they are ideal for remote locations, freezing environments and where a consistent dewpoint is needed.  The down side is they are expensive to buy and not very economical at higher flow rates.

Choosing the right compressed air dryer needs careful consideration. It is important not to over specify and look for a dryer that will not be wasteful. But on the contrary, it is important not to under specify, risking the dryer not performing well will damage expensive machinery and cause downtime.  There are many factors to consider, which are different in each application and use.

Glaston Compressor Services has been designing, installing and maintaining compressed air systems for nearly 40 years. Their team of professional, qualified and experienced compressor engineers provide bespoke compressed air solutions which are tailored to their customer’s specific needs.

Glaston knows it is important to make sure that a compressed air system is meeting the needs of the business, and works in the most efficient way possible. Glaston will analyse the lifetime costs of machines, rather than just the initial costs; taking into consideration running costs, maintenance costs as well as initial set up and machinery costs.  Choosing an air compressor and dryer that will work for you.

For more information about Glaston’s air compressor services, or about air compressor dryers. Visit www.glaston.com

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Compressed Air needs effective Compressed Air Filtration

Most factories around the world rely on compressed air. Having an air compressor on site means that compressed air is readily available and is easy to use. Just installing a compressed air system on site is not good enough and in order for it to work effectively and reliably compressed air filtration needs to be thought about at the design stage. Without effective compressed air filtration the compressed air system will work inefficiently and will inevitably fail.

When air is compressed the air temperature is raised and as the warmer air moves through the system it cools down which produces moisture, which can cause corrosion of the piping system. But it is not just moisture that is detrimental to a compressed air system; other contaminants to a compressed air system include oil from the compressor itself which can also compromise the efficiency of the air compressor system.

For this reason it is therefore imperative that compressed air filtration is taken seriously, any good engineer or system designer will know how to filter contaminants and where to do this within the system.

Modern compressed air filters utilise new filter materials which drastically improve flow capacity and capture even smaller particles than ever. Particles as little as 0.01 µm can be caught, which improves efficiencies to 99.999% in many cases.

With such effective compressed air filtration, air compressors can work for millions of hours uninterrupted. But it is important to understand that even the tiniest of particles can make small holes within the system and can cause serious wear and even system failure.

How to choose an effective compressed air filter?

Compressed air filters are rated per the minimum particle size that their elements will trap. Initially it would be thought to choose the compressed air filter that can trap the smallest element possible; but in fact, this is not the case. If the compressed air filter is too fine it can lead to increased pressure drop through the filter which will increase the energy costs in producing the compressed air. It will also lead to the filter getting clogged up more often resulting in frequent replacement.

Filter manufacturers provide the expected pressure loss and dirt-holding capacity in curves that relate to pressure and flow. This information will help in choosing the right compressed air filter for your system, choosing an acceptable pressure drop and considering the pipe-connection size.

Oil and water in the compressor system will be in mist form, which can pass through standard filters. A coalescing filter will therefore be needed, which can remove particles smaller than solid particles, they range from 1 to as minute as 0.01 ppm (parts per million).

Choosing the right compressed air filtration system is clearly a very complex decision with a lot of considerations to be taken into account.

Glaston Compressor Services has been established for nearly 40 years, their large team of experienced qualified service engineers provides the full service in compressed air systems. Glaston designs, installs and maintains air compressor systems across the whole of the UK. Glaston helps their clients choose an effective compressed air filtration solution designed to meet their individual needs.

Customers choose Glaston based on their strong reputation for excellent customer service and expert knowledge in the field of air compressors. But it is not just air compressors that Glaston works with, Glaston also supplies, installs and maintains nitrogen generators. Glaston’s main aim is to provide a reliable and cost effective solution to all their clients.

For more information about Glaston’s compressor services or any of their other services, visit www.glaston.com.

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Glaston’s Guide to the Perfect Air Compressor Maintenance Checklist

An air compressor is likely to be one of your biggest investments in your business, so keeping it in check couldn’t be more important. Keeping your air compressor running smoothly and efficiently for as long as possible is the key to maximising its longevity and its lifetime costs; this can only be achieved with an effective air compressor maintenance schedule.

Effective air compressor maintenance means that you are more likely to discover issues with your air compressor before
performance is affected or the issue becomes a more expensive problem to repair. Missing regular maintenance may initially seem to save money in labour and time, but in the long run systems lag and eventually break down and ultimately cost more to repair than any savings made by infrequent maintenance.  In this blog we are going to make the ultimate preventative maintenance checklist that all air compressor users should follow.

Ambient

The Ambient or surrounding atmosphere needs to remain as clean as possible to ensure no debris or contaminants can enter the air compressor system. The room needs to be well ventilated to ensure that the air compressor will not overheat.

Cooling Water

If required a good clean supply of water with a regulated temperature and controlled pressure is essential.

Gauges and Controls

All gauges and controls need checking and calibrating regularly. Instruments can be easily affected by moisture and other contaminants, effecting readings.  Checking temperatures and pressures is paramount.

Inlet filter

The inlet filter needs regularly cleaning and checking, an unclean filter increases wear on the components of the compressed air system. The inlet filter also acts as a silencer. Leaking intake causing system contamination can lead to extensive damage to the air compressor system. The filter must be changed at the recommended intervals.

Lubrication

The oil in the compressor is important as it serves three functions, it lubricates the airend, helps clean the compressed air and seals the airend for efficient running. It is imperative to keep a reliable compressor to change the oil and oil filter regularly otherwise at best you will have an inefficient compressor and at worst you will suffer an expensive mechanical failure if the oil goes beyond its working life and breaks down.

Keep it Covered

Keeping the compressor clean is vital to keep it running issue free. Dust is the compressors worst enemy. Cleaning dust with an air gun should be done regularly. When the compressor is not in use, it should be covered.

 Valve Maintenance

In a compressor are many valves which need to be maintained otherwise the compressor performance will deteriorate. In your checklist you must make sure you have a regular schedule of cleaning and checking the valves.

Warranty and Insurance

The safety of a compressor system cannot be ensured if they are not serviced. Compressors come under pressure systems regulations and all insurers will require the compressors to be maintained to keep company insurance valid.

The Environment

There is also an environmental risk of oil leaks if the compressor, condensate and drains are not maintained and if you have a compressor oil leak that goes unnoticed oil will be discharged onto the floor and possibly into an unsuitable drain.

Glaston Compressor Services has been providing compressor services for over 40 years. From designing to installation of a tailored compressed air system, Glaston will provide you with a thorough air compressor maintenance check list to keep your air compressor running to its full potential and prolong its lifetime. Glaston’s team of highly qualified and experience service engineers always strive to provide their clients with the most cost effective solution, considering your compressed air requirements, the energy efficiency ratings. Glaston Compressor Services is proud to be an authorised UK distributor of the renowned yellow boxed HPC KAESER Air Compressors.

Glaston Compressor Services offers many different compressor services other than compressed air maintenance, offering the complete compressed air package, from compressed air filtration to compressed air dryers to compressed air treatment. Glaston also installs nitrogen generators.  Glaston has installed compressor systems in companies across countless different industries, also offering to buy and sell used air compressor systems.

For more information about Glaston’s air compressor services and about creating a suitable air compressor maintenance schedule, or a compressor sales related question visit www.glaston.com

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HPC KAESER COMPRESSOR life cycle management

A HPC Kaeser compressor is a purchase for life – and a decision that we always want you to look back on with satisfaction. Glaston Compressor Services Ltd is an authorised distributor of HPC Compressors in the UK.

Energy efficiency is a top priority.

The purchase price and service costs account for just a fraction of the total lifetime cost of an air compressor system. The biggest item by far is the cost of energy.

HPC Kaeser Compressors UK has been striving for more than 40 years to reduce your energy expenses from compressed air production – but not only that HPC Kaeser also never loses sight of the service and maintenance costs and the constant availability of the compressed air supply, which is why Glaston Compressor Services is proud to be an official distributor of HPC Kaeser Compressors.

Customer satisfaction starts with good advice

Glaston Compressor Services will review your air compressor production set-up and your needs. We have developed systems that permit a precise assessment of how much compressed air you need – and at which quality standards. We will establish a clear understanding of your requirements to develop solutions that will save you time and money.
Air Compressors for these solutions are not one-size-fits-all products. Amongst the numerous design options with a wide power output range, Glaston will find the right air compressor model for you.

HPC Kaeser develop machines with a future

Once your air compressor system is installed, there’s no need to lose sleep over the future costs and service time. Energy efficiency and maximum availability are not HPC Kaeser’s only priorities when manufacturing their air compressor products.

Easy air compressor maintenance, simple replacement of wear parts, long product life – and thus high availability of compressed air – if possible 100% of the time: Glaston Compressor Services Ltd is a proud partner of HPC Kaeser Compressors UK, supplying, installing and maintaining their renowned and trusted yellow air compressors for many decades.

For more information about how HPC Kaeser Compressors can help your business, visit www.glaston.com

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What You Need to Know Before Buying a Used Air Compressor…

If your factory needs an air compressor system, it is likely that you have a budget already defined for its installation. You then have 2 choices in buying an air compressor system: a new air compressor system or a used air compressor system. A used air compressor will save you money, or make your budget stretch further. But a new air compressor system will come with a warranty and peace of mind. Is it worth taking the risk to buy a used system? In this blog we will discuss what precautions and checks should be taken before going for a used compressor system.

Buying a Used Air Compressor

Buying a used air compressor is quite daunting, spending a large amount of money on something that you are not sure about is a huge financial risk. Yes, the price will be considerably cheaper than the current brand new model, but will it end up costing more with repairs, new parts and other maintenance issues? Before you lose hope and decide to spend your money on a lower spec but new air compressor system, consider our guide to buying a used air compressor with confidence:

The Used Air Compressor Guide

A used air compressor can save thousands and work just as efficiently as a new air compressor. So when searching for a used air compressor use this checklist to ensure you make an informed decision:

 Check all the parts of the air compressor are clean, and most importantly, that they are working.
 Check for missing parts.
 Check for sludge build up.
 Run the unit up – does it sound ok, does it run hot?
 Use a power meter to see what energy the unit is pulling, it is high indicating an underlying issue?
 If the air compressor is damaged it may still be worth purchasing, check how much it will cost to repair.
 Is the air compressor still in warranty? This will make repairs much easier.

Should you choose a new or used air compressor system; the decision is one that you will have to ultimately take yourself.

It is a good idea to limit the risks of buying a used air compressor system, whilst still reaping the financial benefits, to consider buying an approved used compressor system from a reputable reseller.

Glaston Compressor Services UK has been designing, installing, and maintaining new and used air compressor systems across the UK for nearly 40 years. Our team of air compressor engineers have years of experience and are available to offer advice on a system that would suit your specific needs. We have a range of HPC Kaeser used air compressors for sale, which can be serviced and maintained by us. Glaston Compressor Services is an authorised distributor of HPC Kaeser Compressors in the UK.

For more information about used air compressor systems, or about any of our products or services, visit www.glaston.com

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Is it really so Important that my Compressed Air is Clean and Dry?

Compressed air treatment is of number one importance in order to run your factory efficiently, both economically and ensuring output. Effective compressed air treatment protects the machinery that you will have spent thousands having designed, installed and maintained. Minimising machinery downtime ensures good throughput. By using clean, dry compressed air, your plant operating costs will be reduced. Within this blog we will discuss the reasons why using clean and dry compressed air is really so important.

In order to understand why compressed air treatment is paramount, it is best to understand what would happen if you didn’t treat your compressed air: Dirt, water and oil- the 3 enemies to your compressed air. These are the 3 nuisances to your air compressors, and letting them inside the system will mean that they will become deposited on the inner surfaces of your fittings and pipes, which in time would cause an increase in pressure drop in the line. Having reduced pressure at the point of use results in a lower performance efficiency, which in the end amounts to money lost in lost production time, and extra maintenance costs. Having water in its liquid form contaminate the pipes leads to corrosion, which of course means parts will need replacing quicker, and particles of corrosion can damage the equipment by blocking valves, fittings and instrument control lines. In cold conditions, the water can freeze, also leading to blockages.

Interestingly, in the past water within compressed air plants was tolerated. To avoid frozen water blocking pipes, alcohol was added into the production line, and heaters were used to separate water and contaminants. But as the use of air compression systems has increased and the introduction of much more sophisticated controls and devices, the need for these not so effective traditional methods of air compressor treatment to be improved, became much greater. The latest air compressor technology has helped to produce clean and dry compressed air by developing different solutions: including compressed air dryers, oil filters, dust filters, water taps.

If oil contaminant is a major problem in your compressed air treatment it will be worthwhile in investing in additional filtration which can remove oil levels down to 0.003 PPM , its always worth speaking to an expert to discuss an effective air compression treatment plan tailored to the needs of your specific factory.

Atmospheric dirt and dust, and water will affect all air compressors whether oil lubricated or oil free; so for all compressed air systems, finding a suitable compressed air treatment plan will always be necessary. Consulting an experienced air compressor engineer will be useful as there are many different options to ensure air purity, such as:

• Aftercoolers: which reduce the temperature and water content of the compressed air.
• Bulk Liquid Separators: these remove condensed liquid in the distribution system.
• Particulate Filters: these removed solid particulate contaminants and separate bulk liquids.
• Coalescing Filters: these remove liquid aerosols and particles.
• Refrigeration Dryers
• Desiccant Dryers
• Membrane Dryers

A well designed compressed air system will ensure that the compressed air treatment takes place before the air enters the distribution system. Often compressed air is used for numerous applications within one factory. So ensuring the compressed air is clean and dry guarantees the most economical solution, and protects all parts of the compressed air system.

Glaston Compressor Services Ltd has a large team of experienced and highly qualified service engineers who service, maintain, supply, and design compressed air systems across the whole of the UK. Glaston’s focus is always on finding the most energy efficient way to meet your output goals, whether in the food, packing, or automotive industry- Glaston supplies air compressor solutions to a diverse range of industry types. Bringing together nearly 40 years in industry, Glaston is the ‘go-to’ name for air compressors, and is proud to be an authorised distributor of the world class HPC Kaeser Compressors.

To talk to an expert about compressed air treatment and how we can help your factory exceed its targets visit www.glaston.com

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3 Benefits of On-Site Nitrogen Generators in The Oil and Gas Industry

Nitrogen gas has countless uses in the oil and gas industry, this is due to its odourless and non-reactive properties. Nitrogen gas is used to move materials down pipelines at oil and gas refineries, to re-pressurise depleted oil wells and even used as a gas barrier to prevent explosions. Nitrogen can be generated onsite; using an onsite generator can increase production and improve job-site safety.

In this blog we are going to discuss the 3 main benefits of producing nitrogen onsite, specifically in the oil and gas industry.

Safety is Paramount

In industry, safety is always a top priority: and in the oil and gas industry this is truer than ever. Safety concerns can be greatly decreased with the use of an onsite nitrogen generator. In situations where an inert atmosphere is necessary, onsite nitrogen generation can significantly increase safety. Onsite nitrogen generators eradicate the need for high pressure cylinders to be handled and stored: a massive benefit in a highly sensitive and dangerous environment.

Increase Production: Reduce Downtime

Being self-reliant in nitrogen gas production eliminates the unnecessary downtime waiting for nitrogen deliveries, the manpower needed to move and store the gas delivered, the admin and paperwork in ordering and paying for nitrogen gas.  By producing the gas onsite, not only are you improving production rates, but you are also eliminating the need for constant nitrogen gas tank deliveries.

Easy to Move or Expand

Probably the most important aspect of the design of nitrogen gas generators for the oil and gas industry is their transportability. This means that the machinery can be simply moved from location to location. It is important to note though, that there are also stationary generators available. In addition to a compressed air supply, nitrogen generators only require a simple electrical supply and with easy operation, the generators only need minimal maintenance. Nitrogen generators can be easily expanded or upgraded, allowing the equipment to grow with increasing demand.

Glaston Compressor Services is always available to discuss your nitrogen needs, specialising in tailored designs, installation and maintenance of nitrogen generators across countless different industries. Producing your own Nitrogen gas can save your company hundreds of pounds versus the traditional nitrogen gas cylinders. With onsite nitrogen generation, the purity and volume of gas generation is entirely controlled by yourself.

Glaston Compressor Services Ltd is also an expert in air compressor design and installation, securing themselves as the UK’s market leader in the field. Glaston is the authorised distributer of HPC KAESER air compressors in the UK.

For more information about on site nitrogen generation, or any of Glaston’s services visit www.Glaston.com

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What do users expect from a compressor system?

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When investing in a new compressor system, users expect maximum efficiency and reliability. Simple as it may sound, these requirements are dependent on many other different factors, including energy costs.

When energy costs for a compressed air system are calculated over the lifetime of an air compressor it equates to many times over the initial investment in the compressed air system. This is true not only to large compressed air systems, but also for smaller air compressors.

For this reason it is vital that energy consumption in a compressed air system in used as efficiently as possible, whilst being able to produce the compressed air to the correct volume, at the required quality. The compressed air system should not just be energy efficient, but must also be reliable. End users rely on their compressed air systems, and their air compressor must ensure maximum availability, always being able to produce compressed air.

The last point that is important to an end user, is making sure the compressed air system requires minimal maintenance costs. A genuinely efficient compressed air system should not incur large maintenance costs. If the compressed air system uses high quality components, and a logical design installation that allows for easy access to maintenance points.

Glaston Compressor Services, draws together their 40 years of experience in air compressor supply, design and installation to provide unrivalled expertise to their clients across the whole of the UK.  Glaston is proud to be chosen as the official resellers for HPC Kaeser air compressors in the UK, and has years of experience in supplying, designing and maintaining those famous yellow boxed machines. Glaston knows that the key to a good air compressed system is an intelligent design, good quality hardware, and an effective maintenance schedule. We can provide maintenance packages tailored to each individual client.

For more information on Glaston Compressor Services visit www.glaston.com

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Compressed Air Treatment: The Importance of Servicing your Compressor with Genuine Parts

When your business relies on an air compressor system daily, it is expensive when things go wrong. At the end of the day, machine down time is lost income: labour, rates etc. still need to be paid even when your compressor is not working, and production has been interrupted. It is however inevitable that your compressed air system will need maintenance to keep it running smoothly. Using an air compressor on a daily basis, will without a doubt, mean that parts will need replacement at some point. When that time does come, it is highly advised, not only by the manufacturer, but also by general opinion, to use only genuine parts.

Using genuine air compressor maintenance replacement parts can be a more expensive option, well initially it will be; but by using genuine parts, it is likely that in the long run you will reduce your air compressor maintenance costs, as well as machinery down time by avoiding future hiccups or part replacement. It is well known that using non genuine air compressor spare parts instead of the manufacturer’s original parts may affect the performance of the air compressor.

With so much money invested in the initial purchase and installation of an air compressor system, ensuring its longevity is essential in making sure you get the longest service life possible, until you have to replace equipment.

There are 3 basic air compressor replacement parts that need to be checked and maintained during air compressor maintenance: These are Air Inlet Filter, Oil Filter and Lubricants. All 3 of these parts have a direct impact on the performance of your air compressor.

1. Air Inlet Filter:

This is the most crucial spare part in your compressed air treatment. The filter protects the engine and compressor element from wear under dust conditions.  By using a non-genuine air inlet filter, it is likely that you are significantly reducing the life of your air compressor.

2. Oil Filter:

The oil filter removes all the impurities from the oil. Air compressor oil generally contains a lot of dust and contaminants, so using an oil filter that is not functioning well can damage the motor or affect performance. By using a genuine oil filter you are ensuring your air compressor has the best chance at an extended lifespan with effective compressed air treatment.

3. Lubricants:

Using genuine lubricants during compressed air treatment, extends the lifespan on your air compressor, reduces maintenance costs by keeps it running smoothly.

Glaston Compressor Services has been designing, installing and maintaining air compressor systems across the UK for nearly 40 years. Glaston, through their track record of many satisfied clients, has managed to secure their role as the UK’s market leader in air compressor services. Their highly skilled professional air compressor engineers have experience in compressed air treatment, air compressor maintenance and other air compressor services. Glaston is an official UK supplier of HPC KAESER Air Compressors.  KAESER Air Compressors is the world’s leader in air compressor systems, with their famous yellow boxes seen in every country in the world.

For more information about Glaston’s Air Compressor Services, Click here

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Minimising Air Compressor Maintenance: Is good air compressor ventilation the solution?

Keeping manufacturing costs as low as possible is crucial when trying to maintain a profitable business. With ever increasing manufacturing costs, it’s always good to know how to avoid things going wrong and avoid hefty and unexpected repair bills. When your equipment is not working, machinery down time costs money.

In this blog we will discuss how to keep air compressor maintenance bills down simply by making sure you have the right ventilation in just 3 easy steps.  Air Compressor ventilation will not only reduce maintenance costs, but it will also enhance compressed air availability.

Step 1:
Location is everything:

Ensuring that you choose the correct ventilation openings is crucial for effective ventilation of the air compression system. The actual location of the ventilation openings is vital: in order to minimise maintenance issues. If air is drawn from outside, it should be affected by the weather as little as possible. For this reason it is essential to install weather protected ventilation openings in the lower half of the installation location’s external wall. These openings should also preferably not face the sun directly.

 Step 2:
Cleanliness is key:

Dust and contamination are your air compressors worst enemy, protecting your compressed air system from dust and contamination is crucial to minimise air compressor maintenance issues. Problematic contamination includes all aggressive and flammable materials as well as emissions from combustion engines. In the air intake zone it is important that trucks and other vehicles that give off heavy emissions are not permitted to enter. Using cooling air filters will help to alleviate some levels of dust and contamination. If the dust and contamination in your factory is very high, you may wish to consider the use of a ‘dust trap’.

Step 3:
Going with the Flow

Correctly sizing and equipping the ventilation openings is vital. The size of the openings will be determined by the power of the air cooled compressors that are installed. Generally speaking the ‘free diameter’ of a ventilation opening should between 0.02 and 0.03m² for every kW of a compressors rated power. This is equal to a cooling air volume of 130 to 230 m³/h. The term ‘free diameter’ is of great importance, the diameter of the ventilation opening will be considerably reduced by weather protector screens, louvres and filters. The diameter can be reduced by 30 – 60% depending on the quality of the selected ventilation system. For this reason it is recommended to use flow- optimised ventilation systems. Reduction in diameter by protection and control devices should always be taken into account. The ventilation system will usually include a bird protection screen, a flow adjustment flap and if necessary: ventilation filters.

If your compressed air system contains more than one compressor, it is highly advised to install a thermostatically controlled ventilation system that will divide the openings according to the position and power of the each compressor unit.

Water cooled air compressors are usually powered by air cooled motors: these radiate heat. Therefore these also require appropriate ventilation. About 20% of the power of water cooled air compressor is converted into heat. This needs to be removed by the cooling air. Thus in this case correctly sized ventilation openings are also vital.

Glaston Compressor Services has been working for nearly 40 years designing, installing and maintaining air compressor systems for businesses across the UK. Establishing themselves as the UK’s market leaders for air compressor services, Glaston supplies numerous brands of compressors and other machinery, and is a UK’s distributor for HPC Kaeser Compressors UK. HPC Compressors UK is recognised as the gold standard in the air compressor industry and has concreted themselves as the market leader in air compressor products being favoured by manufacturers worldwide. HPC compressors in the UK are distributed, installed and maintained by Glaston, who were chosen by HPC Kaeser themselves based on the expertise and professionalism that Glaston has provided clients over their many years in industry. Glaston has been fitting the famous ‘yellow-box’ compressed air system that HPC Kaeser manufactures for 38 years.  For more information on air compressor ventilation, general air compressor maintenance or more information about HPC Compressors UK contact Glaston today www.glaston.com

 

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The true costs of purchasing a compressor – have you looked at the bigger picture?

If you are in the process of investing in a new compressor you will no doubt have obtained a number of quotes. Some may be cheaper than others but, should the initial investment cost be your only consideration in selecting the final compressor? In this blog we consider all of the lifetime costs of a compressed air system that should be evaluated in selecting a new compressor.

Did you realise, that on average the capital investment cost of a compressed air system is only 18% of its total lifetime costs? When comparing new compressor quotes it is therefore imperative that the costs that make up the further 82% should also be closely considered. What the other 82% amounts to will be discussed in this blog.

1) Energy Costs

Accounting for up to three quarters of lifetime costs, energy is by far the largest cost attributed to running a compressed air system.  Energy costs will vary depending on the kW size of the air compressor and the demand for compressed air (how often the compressor is run) and of course the price of energy itself – the electricity rate. Different types of air compressors will vary in efficiency (e.g. fixed speed versus variable speed) as well as different brands of compressors.  In comparing quotes for new compressors it is therefore important to bear all these factors in mind and compare like with like e.g. the same kW sized compressor or the same compressor technology.

As energy costs account for such a significant percentage of the air compressor’s lifetime costs, it is therefore actually the most important thing to consider. In most cases it makes financial sense to spend more on the initial purchase of the equipment if it is more efficient as the lifetime costs are going to be less due to the lower running costs. A good analogy is a car that has a better MPG will cost more than a like for like car with a lower MPG but over the lifetime of the car it will be cheaper to run given the lower fuel costs.

2) Installation Costs

Installing your air compressor amounts to about 2% of its total lifetime cost; this cost is likely to have been quoted in your initial purchase quotation.  This cost may seem like a good place to save money, choosing ‘cheaper’ options, such as cheaper pipe work, or pipe work that is easier to install, therefore reducing installation time and costs. But going for the ‘cheaper’ option, may actually significantly increase the total lifetime cost of your air compressor system in the long run.  The efficiency of piping should be taking into consideration, and also the quality. Having piping that is less prone to leaking, will keep running costs lower over time.

3) Maintenance Costs

To ensure your air compressor runs as effectively and efficiently as it can you should always follow a prescribed maintenance schedule.  Maintenance costs amount to about 7% of a compressed air system’s lifetime costs. Keeping both of these facts in mind, it is essential to investigate the recommended maintenance schedules and costs of servicing the new compressor, as well as the local availability of spare parts, qualified Service Technicians and the cost of breakdowns or emergency service.  Following the manufactures recommended maintenance schedule will ensure that the air compressor system is running to its peak potential.

At Glaston we are experts in the supply, installation and maintenance of HPC KAESER air compressor systems.  We can assist you and guide you through the process of purchasing the right compressor for your business.  Call us today on 01695 51010 and let us help you make the right choice.

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Rocketing Energy Prices….. It’s time to think Compressed Air Energy Savings.

Let’s make your Air Compressor as efficient as possible and save your business money…it’s time to think Compressed Air Energy Savings.

Saving Energy is a win-win, not only does it yield significant financial rewards, but of course it has a positive effect for the environment. There is no better time than now to review your compressed air costs and consider the solutions to reduce costs.

Here Glaston explores numerous solutions that can help make a difference in the efficiency of your compressed air system.

Consider the Current

The best place to start is by examining the performance of your current compressed air system. One way to do this is to call upon the expertise of a compressed air specialist; they can suggest numerous methods that would help reduce associated energy costs with only a simple walk through of your site.

You could also consider undertaking a full compressed air demand analysis, in order to produce detailed data and information. Results can be used to develop specific energy saving solutions tailored to your businesses air compressed system needs.

Look at Leaks

Unfortunately in some cases as much as 50% of compressed air produced can be wasted due to air leaks.  It is inevitable that air leaks will occur in compressed air systems, so clearly it is a factor that should be addressed when looking at energy and cost savings.

 Looking at the figures:

A compressor that runs 24 hours a day, at a rate of 0.10p per kWhr, with a seemly insignificant leak as small as 2mm in diameter could amount to nearly £1,200 worth of wasted compressed air per year. Consider that there is likely to be more than one leak in each air compressed system.

There are simple ways to overcome this:

  • ·         Introduce a leak detection program in-house.
  • ·         Utilise an ultrasonic leak detector (USLD)

It’s also an idea to contact your compressed air service provider and add leak detection to your scheduled maintenance program.

Michael Douglas, Managing Director of Glaston Compressor Services explains “Looking after your current air compressor system is fundamental in ensuring it achieves your compressed air needs in the most effective way.  Regular maintenance and an effective leak detection program is vital.”

Perfect the Performance

It may be that your air compressor is over producing compressed air at times, due to changing shift patterns and the variations in production. It thus would make significant financial sense to adjust compressor performance to suit actual demand.

The majority of compressed air systems include numerous compressors, which can also vary in size. In such systems a master controller is utilised to coordinate the individual machines. With a master controller, compressed air can be effectively managed to suit actual compressed air demand, and prevent over production and waste. Glaston tailors solutions that have the ability to constantly analyse all operations and execute the best combination of compressors to suit the required compressed air demand.

Handy Heat Helps

Each compressor converts all of its electrical energy into heat. The action of compression charges the air inside the compressor with potential energy. Up to 96% of input energy is available as heat. This heat can be used for a variety of uses, such as warehouse space heating, or drying, pre-heating combustion air, or even for generating hot water. In the cooler climate we have in the UK, re-using heat is a clearly a welcome bonus from compressed air systems.

“The heat produced from your compressed air systems is essentially ‘free’ heat and must be fully utilised to reap the financial rewards.” advises Michael.

Maintenance is Mandatory

Following the manufacturer’s maintenance schedule is crucial. Following the checks and changing the required consumables by a qualified service technician is key. Following your prescribed service schedule will ensure that your compressed air system will keep working to its full capability efficiently for your business.

Glaston’s Top Tip

 “It’s all good and well investing in a fantastic compressed air system, but if it’s not maintained correctly it will not operate to its optimum. Prevention is always better than cure.”Michael remarks.

Contact Glaston today to see how we can help ensure your compressed air system is operating to its full potential. 

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Regardless of ESOS Compressed Air Systems are expensive

Michael Douglas, managing Director of Glaston Compressor Services explains why, when considering compressed air systems, only a comprehensive and inclusive approach will result in cost-effective air production.

Compressed air has long been essential for a wide range of manufacturing, process and automation technologies and in some situations its importance is underlined by the fact that users regard it as the ‘fifth utility’. Over time the complexity and efficiency of compressed air systems has dramatically increased and today this is even more important as a result of the Energy Savings Opportunities Scheme (ESOS). ESOS is the UK governments’ response to the EU’s efficiency directive and is essentially a mandatory energy assessment audit applicable to all UK companies with a minimum of 250 employees, or an annual turnover in excess of £42m. It is estimated that generating compressed air accounts for 12% of all industrial energy usage across Europe and whilst the ESOS initiative is a positive step towards a better understanding of energy usage, it does not oblige companies to carry out improvements. However, the commercial reality is that the focus on energy efficiency will only intensify. Therefore, why would any forward-thinking company not wish to implement changes that could result in significant cost-savings, especially over the longer term, giving them a competitive edge, regardless of whether ESOS is applicable to them or not?

Looking at the bigger picture

As the range of compressed air applications grows, so does the demand for increased air quality along with the requirement for optimum reliability and efficiency. However, many ‘systems’ still operate as they did 20 or 30 years ago where, due to a lack of user awareness, they are often referred to as just ‘the compressor’. Therefore, the bigger picture of the system as a whole is ignored. To gain the most from optimising compressed air system efficiency though requires an integrated, system approach. The role of the air treatment equipment, system controller, air distribution network and even the user, should not be under-estimated – they all have a significant effect on system reliability, efficiency and performance.

Greater cost-awareness needed

When talking about energy costs, users are usually able to quote the price per Kilowatt Hour but hesitate when asked how much their plant’s cooling water costs per cubic metre. Ask them how much a cubic metre of compressed air costs and many will be at a complete loss. This is due in part to most purchasing decisions being more concerned with the initial investment cost of the system, instead of accurately considering the long-term operating costs. Even with a perfectly optimised system, energy costs for compressed air production can amount to approximately 71% of total operating costs, whereas the initial purchase investment (excluding installation) accounts for approximately just 15% and for servicing an additional 14%. The larger the compressor the larger the operating cost element becomes.

The once common excuse that it’s not possible to ascertain accurate data cost-effectively regarding actual compressed air costs to assess potential energy-savings is no longer valid. System providers like Glaston have long since offered convenient analysis procedures and equipment. At moderate cost, key data such as pressure, pressure losses, air consumption values and air leakages can be gathered, analysed and documented within a couple of days. Furthermore, with constantly rising energy costs and the potential for increased legislation in the future, Glaston remain committed to producing quality compressed air with minimum energy consumption.

Glaston welcomed the results both from an EU study on energy savings in compressed air systems as part of the EU ‘Save II’ project and the ‘Efficient Compressed Air’ campaign (2002 to 2004). These studies, along with the more recent demands of ESOS are making users more aware of the need to comply and to optimise the efficiency of their compressed air systems.

Another fundamental finding of the EU study was that such potential savings could not be realised simply by improving individual components within a system, they could only be achieved through an integrated system optimisation approach, as most non-optimised systems show weaknesses in all areas.

Deceptive contentions

When the EU study was published, some manufacturers promoted individual products such as workshop compressors, variable speed compressors, or solitary air treatment components that would supposedly provide energy savings of up to 40%. However, significant reductions in energy consumption cannot be achieved simply by adding single components to an existing compressed air system. This would simply be repeating the errors of the past.

The seminars and compressed air audits of the ‘Efficient Compressed Air’ project also confirmed that system optimisation is only possible through an integrated approach.
The Golden Rules – Check everything first!

A detailed overall picture of the existing system is essential when considering new investment in compressed air equipment. The following steps are recommended:

  • Check air consumption, air quality and time dependent operation for all air consuming equipment.
  •  Note location, material type and sizing of the main air supply lines.
  • Produce a schematic diagram of the air production and treatment systems.
  • Use data-loggers, perform a detailed compressed air analysis over a period of at least ten days to include the following data; total air consumption, compressor partial load volumes, pressure measurement upstream and downstream of air treatment equipment and in areas with supply bottlenecks.
  • Assess all leakage losses of compressed air.

Evaluation of this data provides the key information required to calculate actual compressed air costs.

Aim for centralised systems

To achieve maximum energy efficiency, as many items of compressed air equipment as possible should operate at the same pressure. De-centralised compressor systems, network areas operating at a different pressure, or air quality and the use of small oil-free compressors for the purposes of particular processes, should only be considered in exceptional circumstances. In the long-term, such solutions invariably drive up energy costs and unnecessarily restrict flexibility with regards to possible future plans for expanding production or system modernisation.

Problems with compressed air quality usually occur due to moisture and insufficient compressed air drying. These can be identified via pressure dew point measurement and attention should only be turned to the compressor and associated equipment after this measurement has been taken.

Anyone trying to solve these problems simply by installing a master control system will usually find out quite quickly that no ‘off-the-shelf’ solution will work effectively. Compressed air dryers must be precisely tailored to match compressor outputs and the individual compressors should be correctly sized for compatibility with one another. Only then will a master control system be able to select the correct compressor combination at the appropriate moment.

Design strategy

A really efficient compressed air supply can only be achieved through a comprehensive design strategy that meets all specific compressed air requirements and which involves every system element. As a long established compressed air provider with an experienced team of sales/service engineers Glaston is well placed to provide key requirements such as:

  • The monitoring and analysis of existing compressed air installations.
  • Guidance and formulation of energy saving proposals to satisfy ESOS requirements.
  • The specifying and supply of new equipment or services to achieve energy savings.
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Our Christmas closing times

The office will be closed from 5pm on the 23rd December and will re-open on Monday 4th January at 8.30am. 

The team at Glaston would like to wish everyone a very Happy Christmas and a prosperous 2016!

 

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Glaston’s advice on ESOS – an opportunity for business

The Energy Savings Opportunity Scheme (ESOS) is a mandatory energy assessment and energy saving identification scheme for large undertakings (and their corporate groups). In simple terms, an ESOS Assessment requires participants to do the following: – measure their total energy consumption, conduct energy audits to identify cost-effective energy efficiency recommendations and report compliance to the Environment Agency (as the scheme administrator).

The qualification criteria and requirements of ESOS are not entirely straightforward and many organisations will need to take substantive steps in order to comply.

But simple compliance itself misses the point and the objective of ESOS: to identify opportunities to reduce energy use and to cut consumption, emissions and cost accordingly.

Whilst there is no statutory requirement to take action on these opportunities, not to do so is to reduce ESOS to a costly compliance exercise rather than a means to achieve real savings.

Glaston Compressor Services has built a strong brand and positioning in the UK with its range of energy efficient compressed air and nitrogen generator systems.  They recognise that many companies will need advice on how to comply with ESOS in a cost efficient and timely manner as well as putting energy saving opportunities into practice.  Questioned on this, MD, Michael Douglas comments “We are here to assist our customers to bring the projects identified by the scheme to fruition and to overcome the barriers.  Through our expertise in identifying energy saving opportunities, we have made a substantial contribution to increasing the energy and efficiency ratings of many manufacturing plants throughout the country.  Often organisations don’t realise just how financially attractive and beneficial energy efficiency practices can be. We recognise many opportunities in ESOS, both for individual businesses and the UK as a whole.”

The intention is that every audit will recommend cost-effective measures that will save organisations energy and money. Saving money on escalating energy bills will make business operations more efficient and increase competitiveness. Cutting down on energy waste will help ease the strain on Britain’s energy infrastructure and contribute to meeting greenhouse gas reduction targets.

What has to be done to comply with ESOS?

In simple terms, an ESOS Assessment requires participants to do three things:-

  1. Measure your total energy consumption

You must measure your total energy consumption across all buildings, transport and industrial activities. You are required to measure your total energy consumption across a 12-month period (‘the reference period’). Energy consumption can be measured in either energy units (e.g. kWh) or energy expenditure.  You must ensure that at least 90% of your total energy consumption is subject to an ESOS compliant energy audit, a Display Energy Certificate, a Green Deal Assessment or a certified ISO 50001 Energy.

2. Conduct energy audits to identify cost-effective energy efficiency recommendations.

The scheme is estimated to lead to £1.6bn net benefits to the UK, with the majority of these being directly felt by businesses as a result of energy savings.

3. Report compliance to the Environment Agency (as the scheme administrator).

Participants are not required to implement energy efficiency recommendations identified by their ESOS Assessments. However, they will only achieve the financial benefits that arise from avoiding energy waste if they do implement cost-effective recommendations identified.  Reporting compliance to the Environment Agency (as the scheme administrator) MUST be done by 5th December 2015, you must notify the Environment Agency that you have complied with the scheme.

For further information on how Glaston can assist you please contact us now on 01695 51010, or email info@glaston.com

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How economical is your Air Compressor..?

In the modern age, with increasingly expensive electrical costs, the cost of ownership of a compressed air system needs to be looked at in detail. In terms of the whole life cycle costs and not just on the initial capital costs alone.

One way to look at the life cycle costs is to look at the specific power of the compressor – that is, how many kW to produce a set amount of air. The less the kW the more efficient the compressor is.

A very good analogy is to think of the specific power as the MPG (miles per gallon) of the air compressor. Whilst you could buy an uneconomical car with a low MPG you would find that paying a bit extra for car with a better MPG pays for itself very quickly.

As a rule, HPC Kaeser Compressors are 20% more efficient than like for like manufacturers. Even other major compressor manufacturers with large market shares have surprisingly poor efficiency levels.

Here at Glaston, we have the latest data logging equipment with power analysers and cutting edge thermal mass flow meters to accurately determine the efficiency of an air compressor. In one case, a major manufacture was found to have a specific power that was 20% less that its technical data purported it should have. This air compressor has now been replaced with a new HPC Kaeser Compressor CSD125 saving the customer £12,000 per annum.

As a rule when buying any air compressors you need to request the technical data sheets and if it isn’t expressly written on the technical data you should ask for the specific power of that compressor, which should be to ISO1217 Annex C – it’s the only way to compare air compressors.

Please contact Glaston for further information on how to determine the MPG of your compressors! Glaston are specialists in the design, supply, and installation of compressed air systems. We stock a full range of products and are an authorised UK distributor of HPC Kaeser Compressors.

Breaking News: Following on from the Chancellors December budget announcement there was some positive news around Capital Allowance benefits for UK businesses. In 2011/12 we saw the allowance cut from £100k to £25k, which in turn may have had an adverse impact on businesses appetite to purchase capital equipment, however, the allowance has now been increased to £250k until 2015. (http://www.hm-treasury.gov.uk/as2012_index.htm).

Posted in Advice, Air Compressors, Compressed Air, Compressor Control, Energy Use, hpc, HPC Compressors, kaeser, Kaeser Compressors, News | 2 Comments

Preparing your Cooling Water System or Air Compressor for the Christmas break

Often the only time of the year a factory stops production is over the Christmas break, this may be for Christmas Day and Boxing Day or it may be for the whole period from Christmas Day right though until after New Year. Unfortunately this co-incides with some of the coldest weather of the year and when we have compressors that have run all year at + 70 degC shutdown and they cool all the way down to freezing which can give rise to condensation issues on the electrics and motors.

Here at Glaston we offer bespoke solution to help shutdown your cooling water system, or air compressor in the correct manner ensuring it is reliable on restart when required – the main points we consider are as follows:

  • Make sure you shut the compressor down in accordance with the instruction book for the particular piece of equipment. This will ensure that the unit is stopped in the correct manner – don’t be tempted to shutdown using the emergency stop unless there is an actual emergency. Emergency stopping causes the compressor to stop whichever mode it is in and this isn’t good practice as it causes undue stress. By stopping via the emergency stop also means that you / or another have to reset it when starting up again.
  • If possible block any vents into the compressor room to help keep the compressor room above +5 DegC – if you have risk of the room falling below zero then we would strongly recommend additional room heating for frost protection.
  • If you are operating water cooled compressors make sure your water is correctly treated with antifreeze. If not and the temperature drops, as with any water supply, it will and cause damage to the compressor and the cooling water system itself which isn’t easily repaired and can be very costly.
  • Drain all air receivers to make sure there is no condensate left to sit and freeze in cold weather.
  • When re-starting a compressor back up after the break, release the air to the factory slowly and in a controlled manner as rapidly refilling the system could damage your system the compressor and its ancillary equipment.

If you have any question and advice then please contact us here at Glaston.

 

Posted in Advice, Air Compressors, Compressed Air, Compressed Air Condensate, Compressed Air Systems, Compressor Control, Uncategorized | Tagged | Leave a comment

Glaston saves Poppies Europe Ltd £9k

Glaston UK is a leading specialist in air compressor intelligent control, nitrogen generators and energy management systems. With a comprehensive portfolio of energy efficient products and air compressor services, Glaston works with a diverse range of industries including – Power Stations, Recycling, Automotive, Food, Nuclear Power and Aerospace.

Through expertise in identifying energy saving opportunities, Glaston has made a substantial contribution to increasing the energy and efficiency ratings of many manufacturing plants throughout the UK.

A number of Glaston customers have found reductions in their power bills by at least 20%, meaning that once these savings exceed the capital amount, they turn straight into profit. This could happen in as little as 12 months and continue for the life span of the equipment.

Earlier this year, due to their system knowledge and energy saving expertise, Glaston saved UK based manufacturing company, Poppies Europe Ltd, £9k which they had intended to spend on the purchase of a new compressor by identifying air leaks in the existing pipework.

Glaston’s team instructed in leak detection and Poppies maintenance staff set to work fixing them. New 1” pipe work was fitted to replace the old, and new pipe work was installed in areas that had none, but were dependant on compressed air, and were previously being fed by 12mm nylon air line. (This is why the machines were stopping; as the compressed air feed was too weak through such a small diameter pipe, the compressor was struggling to maintain production requirements and leaks). 

Following the introduction of new pipe work and the repair of all the air leaks, the original HPC Kaeser compressor is back to running at 60% of its capacity, providing a highly cost effective, energy efficient solution. This means the site is once again running efficiently and a large monetary outlay was avoided due to Glaston’s knowledge of systems and taking a different approach. 

Danny Jones, Efficiency Engineer at Glaston comments “Air leaks are responsible for 5% of an industry’s energy spend per annum and are too often overlooked due to an “air is free” attitude. Our service engineers are committed to providing a solution to every problem, we pride ourselves on offering fast, expert, impartial advice”.

Similarly, one of Europe’s leading bedding manufacturers, Comfy has seen a significant reduction in maintenance and operating costs due to Glastons recommendations, resulting in Glaston being appointed as their preferred service partner.

Due to an ever expanding production schedule their previous compressor systems were struggling to perform and unreliable.  Comfy contacted Glaston Compressor Services to advise them how to manage the additional compressed air demands.

Glaston recommended the latest HPC Kaeser variable speed CSDX162SFC compressor to provide efficient, cost effective production.  In addition, a high efficiency Tundra dryer was proposed to provide a total package solution.

HPC Kaeser compressors are known worldwide as a class leading, low specific energy consumption compressor, which ensures the lowest possible operating cost. (The lower the specific power the better the MPG of the compressor).  The HPC Kaeser compressor systems are renowned throughout the industry for their reliability and resilience. Quiet in operation and low in maintenance costs they are designed to operate at full load 24 hours a day, 7 days a week.

As well as supplying a new energy efficient air compressor and dryer, a new pipe work system was required for a extension to the Comfy facility. Glaston’s experienced service engineers began by extending the original pipe work system and then installed a new pipe work system into the extended section of the Comfy factory.  They also attached connections to all the production machines providing Comfy with a quickly installed, flexible and energy efficient solution.

Mr Phil Elson, Factory Manager at Comfy’s commented, “Glaston provided a very competitive quote for this work and we were delighted to be able to utilise their services and expertise for the new installation.  We look forward to the new equipment providing a long and efficient life, and look forward to working with Glaston for the foreseeable future.”

Also reporting impressive energy savings is Lancashire based, HR Kilns and Fibreglass.  One of the UK’s leading suppliers of Glass Reinforced Plastic or GRP gratings, they have developed advanced techniques in the use of composite materials that allow the production of sophisticated mouldings suitable for a wide variety of applications.

Managing Director, Darren Weston, comments “Glaston delivered a first class service.  Their knowledge and expertise has saved us a lot of money. We have seen a 10% reduction in our energy bills since they installed the new compressors.  Production reliability has also increased thus resulting in increased turnover”.

Glaston’s team of engineers are experts in the design, supply and installation of energy saving applications. Products include Compressed Air, Compressed Air Systems, Nitrogen generators, Vacuum Pumps, Cooling Water Systems and equipment hire.  

Terry Corringham, Area Sales Manager at Glaston adds “Glaston is proud to be an authorised UK distributor of HPC Kaeser Compressors. We offer our clients bespoke solutions and our service engineers are committed to delivering a first class service”.

End

For further information contact Glaston at info@glaston.com www.glaston.com

For press enquiries contact Emily Shenton on 0161 875 2480 or emily@theconception.co.uk

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Glaston reduces energy bills by 10% with HPC Kaeser compressor.

HR Kilns and Fibreglass, is one of the UK’s leading suppliers of GRP gratings, platforms, drainage covers and GRP flooring.  Commonly referred to as GRP or FRP (Glass Reinforced Plastic or Fibre Reinforced Plastic), they have developed advanced techniques in the use of composite materials that allow the production of sophisticated mouldings suitable for a wide variety of applications.

GRP gratings are approximately half the weight of steel and so will not require the same superstructure to support them, saving time, materials and cost – without compromising on load-bearing capabilities.  The other advantage of using a composite material such as glass reinforced plastic is that the GRP gratings can be cut to size whilst on site and require little or no maintenance.

Privately owned by Darren Weston and established in 2005, HR Kilns and Fibreglass is based in Skelmersdale, Lancashire.

Also based in Skelmersdale, Glaston Compressor Services is a family owned and run business.  A UK leading supplier of Compressed Air Systems and Nitrogen Generators, Glaston has been providing high performance, energy efficient Air Compressors for over 30 years to a range of industries including -  Power Stations, Recycling, Automotive, Food, Nuclear Power and Aerospace.

One of the largest independent suppliers of Compressed Air Systems in the UK, Glaston supplies bespoke total solutions from initial consultation through to full installation and lifetime compressor maintenance.

The HR Kilns and Fibreglass factory was running off an old piston compressor that was unreliable and not at all cost effective.  Compressed air users expect maximum availability and efficiency and the piston compressor was not delivering on either.

HR Kilns and Fibreglass approached Glaston back in 2011 and Glaston recommended the latest HPC Kaeser SX6 compressor to provide efficient, cost effective production.  In addition to this HR Kilns invested in a second compressor the HPC Kaeser SK24, as they were so impressed with the performance of the first one.

The HPC Kaeser’s SK series rotary screw compressors from Glaston deliver more compressed air for less power consumption.  They also combine ease of use and maintenance with exceptional versatility and environmentally responsible design.

The efficiency of a machine depends on the total costs incurred throughout the equipment’s entire service life. With compressors, energy costs account for the lion’s share of total expenditure. HPC Kaeser compressor systems are renowned throughout the industry for their reliability and resilience. Quiet in operation and low in maintenance costs they are designed to operate at full load 24 hours a day, 7 days a week.

Managing Director, Darren Weston, comments “Glaston delivered a first class service.  Their knowledge and expertise has saved us a lot of money. We have seen a 10% reduction in our energy bills since they installed the new compressors.  Production reliability has also increased thus resulting in increased turnover.  We look forward to our current compressors providing a long and efficient life”

Glaston’s team of engineers are experts in the design, supply and installation of energy saving applications.  Products include Compressed Air, Compressed Air Systems, Nitrogen generators, Vacuum Pumps, Cooling Water Systems and equipment hire.  Danny Jones, Efficiency Engineer at Glaston comments “Glaston is proud to be an authorised UK distributor of HPC Kaeser Compressors. We offer our clients bespoke solutions and our service engineers are committed to delivering a first class service to all our clients”.

For further information contact Glaston at info@glaston.com

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Variable Speed Drive Compressors – not always the most efficient solution !

Over the years we have had lots of customers request variable speed drive compressors regardless of the air demand profile of the site and when we ask why they are asking for a variable speed drive they often say one of two things:
“We just want one; we’re putting everything on VSD’s” or “It’s the most efficient type of compressor.”

However, we do not quote a variable speed drive (VSD) compressor just because the customer wants one as it would be irresponsible of us to do so. VSD compressors are more complicated and the VSD controllers have internal electronic losses of 3% which need to be considered. VSD compressors are also a great deal more expensive than fixed speed compressors to purchase.

In an ideal situation the air usage would have a static air demand which was perfectly matched to the size of a fixed speed compressor.

However, if a customer has a varying air demand between 50 and 100% of a compressor output then a VSD compressor may be the most efficient way to generate the compressed air and would warrant the additional capital expenditure.

As already eluded to – a VSD compressor is a very expensive investment and surprisingly in less than 50% of situations are VSD compressors the correct solution.

In an ideal world the proper use of a VSD compressor is the trim compressor in a multiple compressor installation and this is where we get the greatest energy savings.

Some of the important points to consider when buying a VSD compressor are:

1.  A variable speed drive compressor loses about 3% of energy right from the beginning due to the controller losses.
2.  A load/unload compressor (or compressors) with a properly sized tank will be more efficient in nearly every situation.
3.  VSD compressors are a great deal more expensive to work on when they fail.
4.  VSD compressors are more sensitive to the ambient conditions – they’re more fragile than regular compressors.
5.  If you’re getting a VSD due to having a low demand shift and a high demand shift, usually a multiple compressor solution of load/unload compressors are more efficient.
6.  If you want to expand with another compressor, you may have to worry about a control gap.
7.  VSD compressors have a higher initial cost than load/unload fixed speed compressors of the same size.
8.  VSD compressors, if sized correctly, will hardly ever turn off.  That increases your maintenance costs as they will have more run hours on the compressor.

Buying a VSD when you don’t need one would be like buying a supercar to do the daily city commute in.  Sure it will work, but you’ll pay more up front, waste a lot of fuel, the servicing costs will be greater and as the car is more complicated it will have a greater chance of failure. However, had you purchased a city car designed for running at lower speeds then the capital costs are less, running costs are less and repair costs are less. Furthermore as the car is simpler by design it will also be more reliable.

Here at Glaston we will always perform detailed analysis to determine the correct solution for any compressed air system. In many cases retrofitting a VSD controller to an existing compressor will offer all the VSD advantages at a fraction of the cost.

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How a Compressed Air Leak Detector can help save you money

A Compressed Air Leak Detector is a device specifically designed to find leaks in compressed air systems. It works by listening for ultrasonic sounds and is often called an ‘ultrasonic leak detector’.

Compressed Air Leak Detectors are frequently used for compressed air audits. If you’re not familiar with what a compressed air audit is, let me explain.

Compressed Air Audits

The goal of a compressed air audit is to reduce energy costs of your compressor installation. It does so by looking at the supply and demand side of the compressed air system.

The supply side includes your compressors, the pressure set points, the control system (especially when there are multiple compressors) and more. The demand side of the audit looks at things like compressed air usage, changing to equipment that use less compressed air, lowering pressure drop in the piping system, and finding (and fixing) compressed air leaks!

Compressed Air Leaks

All compressed air system have leaks. Leaks can be anywhere including:- pipe joints, valves, equipment and (quick connect) couplings. It is said that in a typical industrial compressed air system, 20 – 30% of compressed air is wasted because of leaks.

When you consider that 70% of compressed air costs is electricity, you will understand that a 20% leakage is a HUGE waste of electricity and money.

A typical 100 kW air compressor system uses around £80,000 per year in electricity, therefore 20% compressed air leakage is the equivalent of £18,000 per year – wasted!

Finding Compressed Air Leaks with a Compressed Air Leak Detector

You can find big leaks simply by listening for them. Do this when the factory is shut down, in the weekend or evening. You will be able to identify many big leaks this way but it is harder to find the smaller leaks and you will not notice any leaks in the overhead piping system.

Most sound coming from a compressed air leak is ultrasonic – it is of such high frequency that we can not hear it. A compressed air leak detector converts the ultrasonic sound to a lower frequency that humans can hear.

As a rule, only 5% to 10% of air leaks are in the piping system and most leakage occurs at the working floor (inside and near the pneumatic equipment). Therefore, it is important to leak test both the pipework and production equipment.

It is easiest to find a compressed air leak with a leak detector that has a headphone and that amplifies and lowers the frequency of the sound. With those devices you can really hear the leak, instead of some beeping sound or indicator.

From Ultrasound Level Readings to Leak Air Flow

The leak detector usually gives a reading in dB (decibel) to indicate the loudness of the compressed air leak. This dB level is converted into a leak size. The conversion factor differs between brands and models but it will always be an estimate and nothing more. For example, a 60 dB reading might convert into a 2 cfm (56 l/min) leak at 100 psi (7 bar).

Buying a Leak Detector

An ultrasonic compressed air leak detector will cost you anywhere between £500 to many thousands. The more expensive are mostly units that can be used for many applications (bearing monitoring, electrical equipment monitoring, hydraulics monitoring, and of course compressed air leak detection). The cheaper units are mostly dedicated leak detectors.

If you would like to discuss compressed air leak detection or buy a ultrasonic leak detector please contact us today.

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Integrated Performance for Maximum Energy Savings

 

An orchestra is far more than simply a collection of musicians. It is the conductor who brings together the individual players to create a single powerful and distinctive sound. The HPC Sigma Air Manager (SAM) available via Glaston plays a very similar role within a compressed air supply system: Utilising the latest master control and web server technology, the SAM is an invaluable tool for ensuring optimised air system availability and energy efficiency.

The SAM controller is designed to not only control energy efficient HPC Kaeser Compressors but all brands of compressors such as Atlas Copco, Ingersoll Rand, Boge and Compair.

 

Adaptive 3-D-Control

The adaptive 3-D-Control detects switching losses (starts/stops), control losses (idling and variable speed drive losses) and pressure flexibility (average increase over required pressure), optimises the ratios between these determining factors and minimises the associated energy requirement. Pressure performance is also improved and average pressure is reduced.

Integrated web server

Using powerful industrial PC-based technology, the SAM is an all-in-one master control system and web server. This versatile system not only ensures energy-saving control, but – thanks to advanced communication technology – also provides unrivalled transparency relating to key data such as operational status, energy consumption and compressed air system costs.



Built-in efficiency

The SAM automatically ensures optimum energy consumption. Users benefit from outstanding energy efficiency and user-friendly operation: Just input the required pressure and compressor performance data – the rest is done for you.

 

Teleservice-ready

The SAM can be easily connected to Glaston Compressors remote diagnostics and demand-oriented maintenance service. Using the modem interface, data is sent directly to Glaston via SMS or a standard telephone line. This feature further enhances system availability.

 

For more information on how Glaston can help you drive down your energy costs please contact us today. Glaston is a UK approved supplier of HPC Kaeser Compressors.

 

 

 

 

 

 

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Heat Reactivated Desiccant Air Dryers

Heat Reactivated Type Desiccant Air Dryers

There are two main types of heat reactivated type desiccant air dryers of which I will talk about each separately, the Internal Type and more modern External Type.

Internal Heat Re-activated Type

Heat Reactivated dryers are used when one needs compressed air of very low Dew point of (-)60˚C or (-)80˚C. In this design, the desiccant is regenerated at higher temperature, along with a quantity of Dry air purge. Approximately 12-15% of the air that passes though is used as purge air. Due to purging with Dry air and thermal regeneration, residual moisture loading on desiccant becomes low and this gives very low dewpoints but the downside is the high requirement of the dryer itself for the purging process.

Characteristics

  • Air capacity: 5 to 5000 NM3/hr
  • Dew point: (-)40˚C to (-)80˚C
  • Operating pressure: 2 to 16 barg

Operating principle

The Drying unit has 2-vessels filled with Activated Alumina or Molecular sieves desiccant. One vessel remains in drying cycle for 4 hours, while other vessel is simultaneously regenerated at atmospheric pressure. Around 12-15% flow of dryer capacity is used as purge for regeneration. Electrical heaters are provided in a central finned stainless steel pipe in both drying vessels. Heating cycle is for 2 hours and in this time hot purge air increases desiccant temperature to over 100˚C. At this temperature regeneration is complete (due to dry air purge). Dewpoint achieved is around (-)40˚C. If a lower Dew point is required more air is purged.

Filters

A Pre-filter with automatic drain valve is provided to remove any physical moisture from compressed air before entering the air dryer. A micronic filter is also provided on the dryer outlet to arrest any desiccant dust particles, up to 1 micron size. Thus, you get absolutely “Clean & dry compressed air”.

Features

  • A fully Automatic unit requiring no attention of the operator. Heaters switch ON/ off and all valves operate automatically.
  • Pressure is equalized to line pressure before changeover of drying vessels. This prevents pressure and flow surge, and, desiccant dusting
  • Lower purge air requirement in comparison to Heatless type dryer.
  • Desiccant life is around 5 years.
  • Internal heaters provide maximum heat transfer efficiency resulting in lower power requirement.
  • Counter current heated dry purge air provides maximum removal of moisture with minimum gas purge loss.
  • Standard units are designed to deliver dry gas / air of (-)40˚C Dew Point. By using more purge airflow, and using Molecular sieves, Dew point of (-) 80˚C can be achieved.
  • Heaters are mounted internally making servicing of the heaters very difficult.

External Heat Re-activated Type

Externally heat re-activated air dryers are bulkier in size. In capacities less than 500 NM3/hr these may be uneconomical.

Characteristics

  • Air capacity: 500 to 6000 NM3/hr
  • Dew point: Up to (-)40˚C
  • Operating pressure: 2 to 16 barg

Operating principle

In this design there is NO LOSS or MINIMAL LOSS of expensive compressed air. Time cycle is 6+6 hours with drying towers filled with desiccant. For regeneration, a centrifugal air blower and an electrical heater is provided. Desiccant is heated upto 100˚C by hot air for complete regeneration and a small amount of purge air is used to polish the desiccant beds to give the required dewpoint.

Comparison with Internal Heat Reactivated Type Dryers

  • Investment cost of these Air dryers is greater than Internal Heat Re-activated Type Dryers but they are more economical in operation so the life time running costs are lower.
  • Work well with dewpoint control switching so the dryer will go into standby mode if the dewpoint doesn’t deteriorate thus saving money.
  • Maintenance on the dryers is simpler as the heaters are externally mounted and not mounted inside the internally heated dryer.
  • If steam is available then this can be used instead of the heater to further reduce electrical consumption costs.
  • Lower purge air requirement in comparison to Heatless and Internally heated type dryer
  • A fully Automatic unit requiring no attention of the operator. Heaters and fans switch on/off and all valves operate automatically.
  • Pressure is equalized to line pressure before changeover of drying vessels. This prevents pressure and flow surge, and, desiccant dusting

Enquiry

Here at Glaston we can supply be-spoke dryer solutions. If For more information of for a quote please contact us.

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Manufacturers Shift Towards Energy Management

The continuous increase in energy prices means that manufacturers must now focus on the most effective way of managing their energy usage and ultimately reducing costs.

According to a joint survey by manufacturer’s organisation EEF and energy provider Npower, the UK’s manufacturers are increasing their investment in energy management towards a sustainable energy strategy. The survey reveals that investment in energy management is not without significant barriers, including the perception of extensive payback periods and businesses prioritising other investments.

Manufacturing companies are now beginning to address inefficiencies in their buildings and processes to try and alleviate rising costs that directly affect the bottom line. The survey showed that around one in five manufacturers are now looking to suppliers for advice on energy savings and efficiency.

Around 25% of all electricity used in UK industry powers compressed air systems. With that in mind, Glaston prides itself on offering reliable and professional advice to each individual client, basing our recommendations on their business needs and ultimately finding the most cost effective solution.

Glaston is an authorised UK distributor of HPC Kaeser compressors due to their reputable energy efficiency ratings and superior performance. Compressed air systems are a costly part of many operational facilities and cost effectiveness is key. Glaston works closely with clients to deliver a compressed air solution that is reliable, high quality and energy efficient. In addition, Glaston offers nitrogen generators that provide up to 40% savings on the cost of buying N2 cylinders.

A comprehensive preliminary assessment is carried out to determine the most cost effective and energy efficient solution. All of the compressed air and nitrogen generator systems provided are tailored to meet individual client requirements.

Energy efficiency is becoming a vital element of business strategies in the manufacturing sector. 96% of the companies surveyed quoted “reduction in energy bills” as a reason for implementing energy management. Therefore, manufacturers are relying heavily on suppliers to provide recommendations on improving energy efficiency and reducing overall costs.

For more information on how Glaston can help reduce your energy consumption and ultimately save your business money, please contact us today. Our engineers are experts in professional installation and maintenance of compressed air systems and nitrogen generators.

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Why generate your own nitrogen?

Why are companies using Nitrogen Generators?

Due to the diversity and cost effectiveness, nitrogen is becoming increasingly popular in a broad spectrum of industry & research laboratories. Nitrogen can be used in a range of applications such as creating inert atmosphere, as a carrier gas, blanketing, purging, packing, filling, and plastic molding. It is also used in tank farms, mobile tankers & containers, agricultural products storages, tyre filling, and related industry processes.

In most applications, the nitrogen pressure required is less than 30 bar. Despite this, high pressure nitrogen cylinders/receivers are commonly used as storage and as a source of nitrogen. These are either large, permanent nitrogen receivers located outdoors and require refilling by large tankers. Or alternatively nitrogen is supplied in bottles and requires careful handling as it is considered hazardous & high risk.

Nitrogen is not often required in its purest liquid form (what industry experts would term 99.99999% pure) and may only be required in a purity of 99.99% or in some cases just 97% purity. The main question to consider is: why pay for a high quality product that is costly to store when you can generate your own in the exact quantities and purity required?

A better, cost effective, solution would be to produce your own nitrogen in house under your control.

How do I produce my own Nitrogen?

Nitrogen is predominantly produced by separating oxygen and nitrogen in air, using the pressure swing adsorption (PSA) process. Dry & oil-free compressed air produced in a Compressed Air System enters the PSA Nitrogen Generator and is stored in a Dry Air Receiver. From here it enters the PSA System where the oxygen is adsorbed by the Carbon Molecular Sieves and nitrogen comes out as a product gas. Necessary measurement and control devices are incorporated to make the Nitrogen Generator fully automatic, as well as to ensure that only pure nitrogen goes to your equipment.

What are the benefits of producing your own N2?

  • It is extremely cost effective – the cost of N2 from a generator is just 20% to 40% of that of N2 from cylinder.
  • The volume and purity of the nitrogen generated is controlled entirely by you
  • No more expensive Nitrogen delivery charges

What can Glaston Compressors Supply?

At Glaston, we work closely with our clients to determine the flow, pressure and purity of nitrogen required. We can then supply and install the system you require, from a standalone nitrogen generator to a complete unit incorporating a generator and air compressors along with all the ancillary equipment.

If you haven’t got room for a nitrogen generator set inside your premises then we can also supply them in an outdoor containerised package. At Glaston, we also have the flexibility to offer our clients nitrogen generators on a rental basis; we work to your requirements and tailor bespoke packages to meet your needs. In addition to the design and supply of the equipment, we have a team of fully trained engineers to meet all the future servicing requirements.

For more information please contact us at Glaston today.

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Do you know your compressors MPG?

In the modern age, with increasingly expensive electrical costs, the cost of ownership of a compressed air system needs to be looked at in detail. In terms of the whole life cycle costs and not just on the initial capital costs alone.

One way to look at the life cycle costs is to look at the specific power of the compressor – that is, how many kW to produce a set amount of air. The less the kW the more efficient the compressor is.

A very good analogy is to think of the specific power as the MPG (miles per gallon) of the air compressor. Whilst you could buy an uneconomical car with a low MPG you would find that paying a bit extra for car with a better MPG pays for itself very quickly.

As a rule, HPC Kaeser Compressors are 20% more efficient than like for like manufacturers. Even other major compressor manufacturers with large market shares have surprisingly poor efficiency levels.

Here at Glaston, we have the latest data logging equipment with power analysers and cutting edge thermal mass flow meters to accurately determine the efficiency of an air compressor. In one case, a major manufacture was found to have a specific power that was 20% less that its technical data purported it should have. This air compressor has now been replaced with a new HPC Kaeser Compressor CSD125 saving the customer £12,000 per annum.

As a rule when buying any air compressors you need to request the technical data sheets and if it isn’t expressly written on the technical data you should ask for the specific power of that compressor, which should be to ISO1217 Annex C – it’s the only way to compare air compressors.

Please contact Glaston for further information on how to determine the MPG of your compressors! Glaston are specialists in the design, supply, and installation of compressed air systems. We stock a full range of products and are an authorised UK distributor of HPC Kaeser Compressors.

Breaking News: Following on from the Chancellors December budget announcement there was some positive news around Capital Allowance benefits for UK businesses. In 2011/12 we saw the allowance cut from £100k to £25k, which in turn may have had an adverse impact on businesses appetite to purchase capital equipment, however, the allowance has now been increased to £250k until 2015. (http://www.hm-treasury.gov.uk/as2012_index.htm).

Posted in Air Compressors, Compressed Air, Compressor Control, Energy Use, hpc, HPC Compressors, kaeser, Kaeser Compressors | 1 Comment

What is Compressed Air Condensate and why must it be treated?

Considerable quantities of condensate are generated when compressed air is produced. However, the term ‘condensate’ is misleading as it could be misunderstood to mean only condensed water vapour. In reality every compressor works like a vacuum cleaner sucking in contaminated air from its surroundings. The contaminates are then held in a concentrated form, in both the compressed air and the water that condenses out of the compressed air. When compressed air is subsequently filtered and dried further condensate is produced.

1. Why treat condensate?

Users who dispose of condensate by simply pouring it down the drain are risking heavy fines. This is because the condensate that has accumulated during the production of compressed air is a highly noxious mixture. In addition to solid particles, condensate contains hydrocarbons, sulphur dioxide, copper, lead, iron and other substances caused by increased environmental pollution. To conform to current legislation the contaminated condensate must be treated before disposal.

2. Condensate from oil-free compressors

Due to increased atmospheric pollution, condensate from oil-free compressors still contains a considerable proportion of oily components. Such condensate often exhibits high proportions of sulphur dioxide, heavy metals and/or other solid particles. This condensate is generally aggressive, having a pH value between 3 and 6. Condensate of this quality cannot be disposed of as wastewater, even though this is often claimed.

3. Specialist disposal

Of course, it is possible to collect the condensate and have it disposed of by a specialised company but this would be at considerable cost.

4. Treatment processes

a) Condensate from Oil Flooded Compressors.

Normally condensate is treated via gravity fed carbon filters sometimes with, and sometimes without, separating chambers where the oil layer that floats on the top can be automatically skimmed off. This method saves up to 95 % of the costs involved compared to using a specialised company to dispose of the condensate.

b) Condensate from oil-free compressors

In many cases the condensate from oil-free compressors must be treated with a chemical separating process. This includes pH neutralization through the addition of alkalis and the binding and concentration of heavy metallic components in a filter cake which has to be disposed of as hazardous waste. This process is by far the most complex. Special disposal approval must be obtained that covers not just possible oil components in the condensate but also concentrated pollutants drawn in from the ambient air. The latter can contaminate the condensate considerably.

At Glaston we can offer a wide range of condensate treatment methods by numerous manufacturers to best suit your requirements.

To ensure you meet your environmental regulations please feel free to contact us at Glaston for help and advice on your condensate treatment requirements.

For peace of mind Glaston is registered to ISO 14001 for environmental management.

Posted in Air Compressors, Compressed Air, Compressed Air Condensate, Compressed Air Systems, Compressor Control | Leave a comment

Why HPC Kaeser Compressors are the best

HPC Kaeser Compressors offer superior performance, durability, and energy efficiency. They are available from 2.2kW right up to 450kW, with capacities from 9 to 3,044 cfm, and pressures up to 15 bar. All units are fully packaged and are ready for operation.

Designed for Maximum Reliability

In every machine HPC Kaeser builds you will find many features to enhance reliability and simplify maintenance, from the heavy gauge steel frame with double vibration isolation to the quick fluid change feature. Kaeser airends are built to stand up to many years of tough service. TEFC motors are standard and we use pipe instead of lower cost tubing. A well-planned cabinet design and component layout reduce noise and footprint with easier access during preventive maintenance. The list goes on. HPC Kaeser compressors go beyond expectations.

Lower Long Term Costs

Energy costs are a significant portion of any compressed air system’s total lifetime cost.  In fact, the amount of energy required to run a compressor for just one year can exceed the compressor purchase price. Over a period of 10 years, energy normally totals 70% of the overall costs.

Since HPC Kaeser’s energy-saving screw compressors delivered up to 20% more air per kilowatt, the cost-efficiency is clear.

 

 

 

 

 

 

 

For more information on our HPC Kaeser Compressors please do not hesitate to contact us. Glaston also has a range of used air compressors for resale or hire.

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SAUER Air Compressor installation

For 10 years our new customer had used two Ingersoll Rand 350 bar piston air compressors to maintain the 350 bar and 40 bar operating pressures. Unfortunately, both units failed within a short space of time and hire equipment was brought in at a considerable expense.

Subsequently, Glaston were invited to review the high pressure system following a successful project to overhaul the general purpose 7 bar air. This review resulted in the installation of four 160kW HPC energy efficient air compressors. 350 bar and 40 Bar Compressor installation

As opposed to offering two new 350 bar compressors, it was deemed more cost effective, from both a purchasing and operating perspective, to supply a 350 bar compressor to fulfill the 350 bar requirement. And a 40 bar unit was supplied to fulfill the 40 bar air requirement. 350 bar and 40 Bar Compressor installation

Once the site understood the benefit to generating compressed air at the pressures actually required, Glaston put forward a 350 bar SAUER piston compressor and a 40 bar SAUER piston compressor. SAUER are renowned worldwide for the superior build and reliability of high pressure air compressors. Additionally, SAUER air compressors are used extensively through out the world serving general industry, shipping and many navies. 350 bar and 40 Bar Compressor installation

Following a rigorous tendering process, two SAUER units were installed in the summer of 2010 and have been successfully operating since.

If you would like to find out more about our air compressor installation services then please contact us.

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Compressed Air Systems – Summer Running

As we start to approach the warmer summer months compressed air systems need to be adjusted for the warmer ambient temperatures.

Just as we need to ensure compressors and ancillary equipment, such as dryers and filters, run in ambient conditions that prevent frost damage during the cold winter months the opposite is true when the weather turns warm.

It is essential that compressors and dryers are all serviced in accordance with the manufacturer’s recommendations. Old oil that is past its working life loses some of its thermal properties and it becomes more difficult to remove the heat generated during compression. Blocked oil filters also restrict oil flow around the compressor which again prevents the cooling system from working. A common missed service item is the cleaning of the oil and air coolers. If the oil cooler is blocked the compressor will run hot and if the air cooler is blocked the temperature of the compressed air leaving the compressor will be too hot and this will put a lot of strain on the filtration systems, often leading them to fail.

Compressors that are running over the ideal design temperature will also suffer from additional oil consumption. This impacts the system in two ways. Firstly it means that the compressor needs constantly topping up with oil (this is costly) and secondly it puts more strain on the filtration systems as they have to remove this additional oil passing through with the compressed air.

Compressors running hot will also suffer from increased bearing degradation in the airend and motor. Premature bearing failure of this type is extremely costly. IF you are fortunate enough to have an HPC compressor then we can offer special exchange AirEnd prices at a significantly reduced cost provided the airend still rotates. However, if you operate other manufacturer’s units then you may be forced to buy new AirEnds at full cost which represents a large portion of the cost of a new compressor!

Obviously, even if the compressor is serviced to the manufacturer’s recommendations it is imperative that the ventilation of a compressor room is suitable to allow fresh air in. Warm ambient conditions coupled with poor ventilation will soon result in overheating problems. A suggestion to improve room ventilation is extraction fans used in conjunction with room thermostats (so they only run when required) or ductwork systems to duct out the warm air and draw cool air in.

For further advice on running compressors in the summer please contact us at www.glaston.com

Posted in Advice, Air Compressors, Compressed Air, Compressed Air Systems, Compressor Control | 1 Comment

A reliable solution to portable compressed air requirements

HPC KAESER Portable Screw Compressors are powerful, mobile machines for providing compressed air in a number of applications. These include, construction sites or in industry for applications such as road breakers. In addition, the reliability of these portable compressors makes them ideal as temporary machines, for situations where compressed air requirement is greater than the current capacity. For example, if you current compressor is out of action for any reason, a HPC KAESER diesel driven portable unit may be the ideal short term solution. A wide range of models and options cover every demand, from power tools to auxiliary electrical supplies for lighting and welding.

The HPC KAESER partnership provides a wealth of experience and expertise with a range of portable compressors and accessories providing ideal solutions to the varied needs and demands of the U.K. portable compressor market.

From the small compact M13 with a capacity of 1.2m3/min (42cfm), that can be transported in the back of a small vehicle right up to the high-performance M270 delivering 27m3/min (953cfm) at 7bar we can help.

As an option, all machines can be fitted with a tool lubricator for picks and breakers, two of the standard uses for a portable compressor. Especially designed for this purpose the unit adds a biologically degradable lubricant and defrosting medium to the compressed air. This reduces wear on pneumatic tools, increases their life and guarantees reliable operation. As well as lubricated air for tools, dry, cool or heated air can be produced for sand-blasting and concrete repair.  Another treatment unit can even provide air of breathing quality. If a special distributor is fitted, air of differing qualities can be supplied in parallel.

Several models are available with an integrated generator for applications requiring mobile electric power (for example PE welding of plastic piping, powering electric tools and submersible pumps or site illumination). The generator can supply both three-phase and single-phase power via an overload protection switch. With this equipment, the unit becomes a versatile mobile power station.

Over the years Glaston have supplied units to the UK as well as export for use on oil fields and off shore oil rigs as spark arrestors and chalwyn valves are freely available for the HPC KAESER units.

For any further information on our range of HPC Kaeser portable compressors please contact us at Glaston.

Posted in hpc, HPC Compressors, kaeser, Kaeser Compressors, Portable Compressors | Tagged , , | 1 Comment

Benefits of Storage in a Compressed Air System

Storage in a compressed air system performs several functions, and is a critical part of any properly designed air system. When correctly applied, storage can improve energy savings, air quality, and pressure stability; as well as reduce maintenance costs and extend the life of the air compressors. Continue reading

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Power is nothing without control – new 3D control takes compressor control to a whole new dimension.

HPC Compressors and  Kaeser compressors are widely acknowledged as the most efficient and reliable compressors that money can buy. Built in Germany to rigorous standards HPC / Kaeser compressors will give decades of satisfaction. However, to maximize the efficiency of any compressor system proper control is essential, after-all, if you have an efficient car why would you negate this by taking the long route on every journey? Continue reading

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Completely Redesigned ESD Compressors with SFC Options

Introducing HPC / Kaeser redesigned ESD rotary screw compressor series. Available in 160kW and 250 kW variants providing flows from 816-1522 cfm and pressures to 15 bar. The ESD series has been redesigned for increased efficiency and improved specific performance, as the one-to-one direct drive design includes a premium efficiency drive motor with three PT 100 temperature sensors. Continue reading

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SIGMA Control 2 – Integrated Intelligence – Power is nothing without control

HPC KAESER’s revolutionary modular concept takes compressor controller technology to the next level and beyond. Welcome to the world of SIGMA Control 2. It’s now over a decade since HPC KAESER introduced its ground-breaking SIGMA Control internal compressor controller, the innovative “PC in a compressor.” The integration of an industrial PC as standard in every energy efficient rotary screw compressor not only enabled cost-effective control, but also allowed networking capability between individual units and with master control systems. Continue reading

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Leading From the Front – the New SK Series Compressors

Discerning compressed air users expect maximum availability and efficiency, even from smaller compressors. In addition, there is growing demand for seamless connectivity with master control systems, so that users can benefit from the enhanced efficiency and load distribution that this technology has to offer compared with simple, stand-alone systems. Continue reading

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Which type of Nitrogen Generator is suitable for you?

Dependent on purity, flow rate and a number of other considerations there are many options to supply nitrogen. The indicative optimal supply options are shown below. Consultation with Glaston Compressors will result in the preferred solution for your specific on-site nitrogen generator supply needs. Continue reading

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New Energy Efficient HPC Compressors Released to Market

HPC is part of a global operation through its long established and extremely successful partnership with KAESER Kompressoren GmbH. As part of the continual drive to improve the specific power and drive down user costs HPC and Kaeser have released two new updated compressor models, the CSD and CSDX. Continue reading
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Chemical Industry Awards June 2011

Glaston Compressors were kindly invited to a prestigious awards ceremony by their client Rockwood Additives. The Chemical Industry Awards ceremony was held in Birmingham in the historic Great Hall in the University of Birmingham on June 23rd 2011. Continue reading

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F-Gas Certification in the Compressed Air Industry

Glaston Compressors is helping its clients comply with the EU F-Gas Regulations, ensuring that their refrigerated air dryers and process water chillers are properly monitored and maintained by F Gas certified engineers. All of our engineering field services refrigerant team are fully qualified and certified by F-Gas for the Safe Handling of Refrigerants. F-Gas Certification in the Compressed Air Industry Continue reading

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Energy Savings by Optimising Pipework

Millions on pounds are needlessly wasted per annum due to aging or poorly maintained air distributions systems which allow valuable energy to escape unused. Unfortunately resolving these issues can be costly and may involve a lot of hard work, but as they say, the more you put in the more you will get out! Energy Savings by Optimising Pipework Continue reading

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