Production at the New Center Stamping plant is highly dependent on access to a reliable source of compressed air. Only a 25% reduction in available pressure causes air – dependent machinery to automatically shut down.
Some of the equipment dated as far back as the 1920’s when the building – made famous in the movie 8 Mile – was constructed. Breakdown and resultant repairs of the aging system was a frequent cause of interruptions to production. When a production critical unit broke down and replacement parts were no longer available, a system wide upgrade was considered.
The Energy Alliance Group of Michigan (EAG) was tasked with developing a comprehensive replacement for New Center’s piecemeal and outdated compressed air system. EAG teamed up with an alliance partner, Air Technologies, for a unique solution known as DirectAIR®.
The staff at New Center noted the solution included the following list of unexpected benefits:
Dramatic noise reduction – with the compressors now housed in a separate structure outside the building, the noise level within the building dropped dramatically.
Air consumption computer controlled – less waste and a significant reduction in electrical use due to computer monitored air production resulting in optimum air volume with no excess.
Improved space utilization – the former compressed air equipment will be removed and the now free space will be converted into a new storage area.
Zero down time – all maintenance and repairs of the DirectAIR® equipment are included with the service and the equipment is constantly monitored offsite. Automated system alerts provide DirectAIR® service technicians with the spontaneous information they need that allows them to show up for service before the New Center staff is even aware a problem is developing. Backup systems are also contained in the unit to guarantee zero downtime.
Source: Energy Alliance Group