Is "waste" being overlooked in your factory?

Examples of Waste:

<Piping>

1. Leaks: Compressed air systems frequently experience leaks in piping and connections. These leaks are often invisible and tend to be overlooked, but they lead to unnecessarily prolonged compressor operation, resulting in increased costs.

<Air Compressor>

2. Excessive pressure: Running the system at higher pressure than necessary results in wasted energy consumption. Additionally, excessive pressure can shorten the lifespan of equipment.

3. Incorrect system sizing: Using compressors that are larger than required can lead to energy waste.

4. Built-in dryer type: In the case of air compressors with a built-in air dryer, the environmental conditions in Thailand often lead to frequent issues, resulting in reduced dryer performance or early failures. This also tends to cause unexpected costs and a shorter equipment lifespan.

<Air Filter & Auto Drain>

5. Deterioration of air filters: Air filters, which are used to remove impurities (water droplets, debris, oil mist, etc.) from the compressed air discharged from compressors, are often overlooked when element (consumables) inside deteriorate. Clogged filter elements cause increased pressure loss, leading to higher compressor load and costs. In the worst case, damaged filter elements may cause fragments to enter equipment, resulting in breakdowns and costly repairs.

6. Deterioration of auto drains: Auto drains, which discharge water collected by air dryers, may fail, causing reduced cooling efficiency in the air dryer or drainage backflow into downstream systems.

<Air Dryer>

7. Insufficient Capacity of Air Dryers: In the selection of air dryers, it is often observed that models lacking the required capacity are being used. Insufficient capacity can lead to inadequate dehumidification, creating a risk of condensate discharge at the end of the line. Such discharge can contribute to equipment failures, defective products, and unnecessary cost increases.

8. Contamination of the condenser: In air-cooled refrigerated air dryers, depending on the installation environment, dust may accumulate on the condenser’s mesh or fins, and oil may adhere to the surface. This can lead to issues such as inadequate cooling of the air and drain discharge at the end point, resulting in unnecessary costs.

Solutions:

<Piping>

1. Regular inspections and repairs: Identifying and repairing leaks reduces waste. Regular inspections are crucial for early detection of leaks.  ⇒Here's SUGGESTION!

<Air Compressor>

2. Optimization of pressure: Set the pressure accurately to avoid excessive pressure. Introducing pressure relief valves or inverters can enable efficient operation. ⇒Here's SUGGESTION!

3. Proper equipment selection: Select compressors based on load requirements for efficient operation. ⇒Here's SUGGESTION!

4. Separation of Air Compressor and Dryer: In Thailand, compressor rooms are often high-temperature environments (40–50°C), where built-in air dryers are especially prone to heat buildup and frequent breakdowns. Additionally, parts are often not readily available within Thailand when failures occur, leading to longer repair times and increased costs. Therefore, we recommend preparing a standalone air dryer from the outset.

<Air Filter & Auto Drain>

5. Daily checks and regular replacements: It is necessary to check the daily differential pressure gauge readings and whether drain discharge is occurring, as well as to regularly replace the elements.  ⇒Here's SUGGESTION!

6. Daily checks and cleaning: Check the drain window for water accumulation & discharging possibility, and perform regular cleaning, especially for disk-type where impurities can easily get stuck. ⇒Here's SUGGESTION!

<Air Dryer>

7. Recommendation for Proper Model Selection: We recommend selecting models with ample capacity by using accurate data regarding air compressor capacity, required dew point temperature, inlet air temperature for the dryer, and ambient temperature at the installation location.  ⇒Here's reference page (Model selection)

8. Regular condenser cleaning: Most issues are caused by poor refrigerant heat exchange due to condenser contamination. Depending on the level of contamination, performing air blowing on the condenser protection net (mesh) and fins weekly to monthly can help avoid most of these problems. In cases of severe oil contamination, high-pressure cleaning by a professional may be necessary.

Examples of Waste:

1. Running under fluctuating loads: Using fixed-speed chillers under varying load conditions can waste energy, especially when the chiller runs unnecessarily during periods when cooling isn’t needed.

2. Dirt and impurities: Long-term use can cause dirt buildup in cooling water pipes (water-cooled condensers/dual pipes) or aluminum fins (air-cooled condensers). Scale and impurities inside heat exchangers (e.g., plate-type or shell & tube) also reduce cooling efficiency, leading to increased energy consumption.

3. Cooling issues with cooling tower use: Due to the principle of cooling towers, the water temperature can only drop to 3–4°C below the ambient temperature. In Thailand, this can lead to cooling insufficiencies, especially during the summer, causing production equipment failures, scale buildup due to water quality deterioration, and other related issues. These factors can result in production delays and equipment damage.

Solutions:

1. Upgrading to inverter models: Monitor system operations and adjust based on the load. Replacing with models that adjust output linearly to match real-time demand can significantly improve energy efficiency. ⇒Here's SUGGESTION!

2. Regular maintenance: Perform periodic cleaning of water/air-cooled condenser parts (by flushing or air-blowing). Regularly manage and replace chiller water to prevent scale buildup, and Installation and Regular Disassembly and Cleaning of Strainer.

3. Switching to a chiller: By replacing with a chiller, it is possible to maintain a stable water temperature and clean water quality throughout the year. ⇒Here's SUGGESTION!

Examples of Waste:

1. Excessive vacuum levels: Maintaining vacuum levels higher than necessary results in wasted energy. Similarly, using unnecessarily powerful vacuum pumps wastes energy.

2. Leaks: Like compressed air systems, leaks in vacuum systems result in energy waste.

3. Multiple small, fixed-speed pumps running continuously: In cases where multiple small fixed-speed vacuum pumps are running continuously at various locations, this can lead to excessive energy consumption without regard for varying loads.

4. Use of ejectors: Ejectors that use compressed air from energy-hungry air compressors to generate vacuum are inefficient.

Solutions:

1. Setting appropriate vacuum levels: Set vacuum levels accurately and avoid excessive operation. Adjusting vacuum levels based on actual needs improves energy efficiency. The inverter type can be set to desirable vacuum level, allowing you to avoid excessive energy consumption.  ⇒Here's SUGGESTION!

2. Leak repairs: Regularly inspect and maintain vacuum systems to detect and repair leaks early.

3. Centralized inverter-controlled operation: Centralize the vacuum source and supply only the required amount of vacuum at an optimized pressure level. This reduces energy consumption and maintenance costs. ⇒Here's SUGGESTION!

4. Introduction of small vacuum pumps: Instead of using compressed air to generate small amounts of vacuum, install appropriately sized small vacuum pumps for greater efficiency. ⇒Here's SUGGESTION!