Success Stories

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  • Manufacturing

    An multinational producer of paper-based consumer products

    USA

    • The site was running old and inefficient compressors that needed replacing
    • Existing configuration did not have monitoring functionality – or even a system controller
    • A need for greater clarity and understanding with regards to the volume of air the site was using
    • SCADARTM was used to audit the compressed air system and ascertain exactly how much air was being generated in relation to demand – the results of which now inform the site’s ongoing strategy
    • AIRMATICSTM was installed to monitor the performance of two newly installed 160kW fixed speed compressors and one 160kW VSD compressor on a 24/7 basis; now the team understands the cost and carbon emissions of the entire compressed air system at all times
    • Power and flow continually monitored and controlled to ensure that the system is perpetually running efficiently 
    • AIRMATICSTM has saved the manufacturer £64,500 per year in energy bills
    • AIRMATICSTM has cut compressed air energy usage by 258,000 kWh
    • Almost 40 tonnes of carbon emissions have been cut each year
    Key Figures (Per Year)
    • Energy Savings

      258,000 kWh

    • Cost Savings

      £64,500 per year

    • CO2 Savings

      40 tonnes

    Final Thoughts

    “The customer really wanted to update their compressed air system, reduce their environmental impact and cut energy costs. By integrating AIRMATICSTM in tandem with installing modern compressors, they’ve been able to do just that. Now, every aspect of their compressors is monitored, which is providing invaluable data and insights on an ongoing basis.”

    AIRMATICS spokesperson

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  • Lumber

    West Fraser

    USA

    West Fraser
    • The customer had five compressors operating independently, which was resulting in system inefficiencies with multiple compressors loading and unloading simultaneously.
    • The system was experiencing large pressure swings depending on air demand.
    • AIRMATICSTM was installed, which: Saw the system’s master controller – the AERO – immediately synchronize all five compressors and ensure that they were working together efficiently and harmoniously;
    • Enabled the customer to use IoT remote monitoring technology to continuously monitor its compressed air system’s efficiency levels – and incorporate email notifications to immediately alert the customer when they fall below set parameters;
    • Provided the customer with sight of its system’s flow and power levels;
    • Introduced IoT remote monitoring technology that now alerts the customer by email when efficiency levels have dropped.
    • Reduced compressed air energy bills by $52,560 a year.
    • Cut compressed air power usage by 657,000 kWh a year.
    Key Figures (Per Year)
    • Energy Savings

      657,000 kWh

    • Cost Savings

      $52,560

    Final Thoughts

    CMC developed a SMART-TAG gateway interface solution to the ELGI NEURON controller, making it very easy to connect the customer’s compressors to the AERO master controller. Once the system was started, it delivered immediate savings and effectively matched compressed air output with demand.

    Spokesperson for AIRMATICSTM

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  • Automotive

    A luxury SUV manufacturer

    UK

    Luxury SUV Manufacturer
    • Two compressor plant rooms approximately 500 metres apart, each with a system controller in place.
    • Both rooms had a combination of centrifugal and rotary screw compressors feeding a common pipe network.
    • Depending on air demand they would often ‘fight’ each other, which caused volatile compressor behaviour and created considerable system inefficiencies.
    • AIRMATICSTM was installed, which: Harmoniously controlled the compressors in both rooms, making sure that output was both balanced and efficient at all times;
    • Provided accurate monitoring of demand side pressure across both rooms through fibreoptic cabling connected to the AIRMATICSTM AERO – the master control unit;
    • Established and maintained the most efficient mix of compressed air from the variable speed rotary screw and centrifugal compressors during every operational minute;
    • Enabled plant operatives to access performance data and analyses at all times, from any location and via and device.
    • Created annual energy savings of £63,750.
    • Established system efficiency and ensured that ALL compressors work harmoniously across two locations.
    • Cut energy usage by 425,000 kWh.
    Key Figures (Per Year)
    • Energy Savings

      425,000 kWh

    • Cost Savings

      £63,750

    • CO2 Savings

      17,000kg

    Final Thoughts

    The complexity of this system, given its dual compressor rooms, meant that it was nowhere near achieving its true potential. Now, with AIRMATICSTM and its pressure balancing feature, we’ve radically changed this.

    Spokesperson for AIRMATICSTM

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  • Automotive

    A luxury car engine plant

    UK

    Luxury Car Manufacturer
    • The manufacturer’s existing lubricated rotary screw compressors were becoming old and reliable, so the decision to install a centrifugal compressor was taken by the customer in order to take the load away from the aging asset.
    • However, the reconfiguration created a new dilemma: how to effectively and efficiently control a mixture of different compressor technologies.
    • AIRMATICSTM was installed, which: Provided complete and harmonious control of the plant’s combination of fixed and variable speed compressors, and its new centrifugal asset;
    • Enabled plant operatives to measure power and flow levels inside the plant room and remotely, which has helped make the entire system more efficient and healthier.
    • Implemented remote monitoring, which has improved system efficiency and health.
    • Created annual energy savings of £44,000.
    • Cut energy usage by 440,000 kWh.
    Key Figures (Per Year)
    • Energy Savings

      440,000 kWh

    • Cost Savings

      £44,000

    • CO2 Savings

      117,333 kg

    Final Thoughts

    The ability of the AIRMATICSTM AERO to manage a mixture of compressors of different ages and brands, all of which are located in the same plant room, is what sets it apart. This prominent car manufacturer’s compressed air system is significantly more efficient than it was prior to the installation.

    Spokesperson for AIRMATICSTM

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  • Manufacturing

    A UK kitchen manufacturer

    UK

    Kitchen Manufacturer
    • 10 compressors operating across two locations, all of which were being managed by two system controllers and feeding one common pipe network.
    • Both system controllers were incompatible with the four variable speed drive compressors in operation, the result of which would often see usage rapidly shift from 0 per cent – 100 per cent and back again.
    • Without physically entering either of the two plant rooms, which were situated 500 metres apart at either side of the factory, none of the operatives had any visibility of system performance.
    • Downstream air was not being monitored, which meant that if a dryer failed the system was exposed to moisture contamination – a situation that would have resulted in production issues and downtime.
    • AIRMATICSTM was installed, which: Meant that one controller could harmoniously manage all 10 air compressors in both locations;
    • Provided 24/7 visibility of the system via the system’s remote visualisation feature;
    • Additionally, dryer alarms and monitoring capabilities, which covered air treatment differential pressure and system dew point, were installed in both plant rooms and incorporated into the AIRMATICSTM remote visualisation display to help operatives minimise downtime.
    • Brought the management of 10 compressors – in multiple locations – under one controller.
    • Created annual energy savings of £120,000.
    • Cut energy usage by 800,000 kWh.
    Key Figures (Per Year)
    • Energy Savings

      £120,000

    • Cost Savings

      800,000 kWh

    • CO2 Savings

      74,040 kg

    Final Thoughts

    This system was in a poor state until AIRMATICSTM brought it under control. As a result, the customer has now benefited from substantial energy savings.

    Spokesperson for AIRMATICSTM

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  • Food & Drink

    Golden State Foods

    USA

    Golden State Foods
    • The customer’s compressed air system was not properly synchronized.
    • Compressors were running at higher pressures than required – even when air demand was low.
    • Due to a lack of KPIs, the customer was unable to effectively monitor the health and efficiency of its compressed air system.
    • AIRMATICSTM was installed, which: Has enabled the customer to ensure that its compressors are continually synchronized – and therefore effectively controlled – at all times;
    • Now provides 24/7 system transparency and asset accountability by continuously monitoring the health and performance parameters of the entire system and individual compressors;
    • Helped the customer establish that by replacing one of its fixed speed compressors with a variable speed drive compressor, it will generate additional energy and carbon savings.
    • Improved system health and efficiency by synchronizing ALL compressors at ALL times.
    • Provided 24/7 system transparency and asset accountability through remote monitoring.
    • Cut the customer’s compressed air energy bill by $57,600 a year.
    Key Figures (Per Year)
    • Energy Savings

      320,000 kWh

    • Cost Savings

      $57,600

    Final Thoughts

    The customer took a step-by-step approach to improving the performance of its compressed air system, which we really liked. Firstly, we made sure that the AIRMATICSTM AERO system was able to monitor pressure, flow and dew point. We then added controls to efficiently manage the existing fixed speed compressors, the data from which illustrated how, by replacing a fixed speed compressor with a variable speed drive asset, they could make even further savings – something that is now being carried out towards the end of this year.

    Spokesperson for AIRMATICSTM

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  • Food & Drink

    Cooper Farms

    USA

    Cooper Farms
    • The customer had introduced a new compressor to its existing compressed air system – but it was located 650 feet away from the other operational assets.
    • The system included a combination of compressors that ranged in horsepower and covered both fixed speed and variable speed drive – none of which were working together as efficiently as they could be
    • To manage the system, the customer was using various controllers – all of which differed in age and capability
    • AIRMATICSTM was installed, which: Incorporated Ethernet over a 2-wire transmitter and receiver, allowing the customer to span the 650 ft with one uninterrupted run of wire. Prior to this, the Ethernet cable would have required an Ethernet switch to join two traditional Ethernet cables together. As an underground installation, there was no way to do this. Without the 2-wire transmitter and receiver, this installation would not have been possible;
    • Through the inclusion of SMART-TAG interfaces, enabled every compressor within the system to synchronize effectively – regardless of its location;
    • Data link connections for three different controllers were developed for this installation, all of which require minimal connections inside the electrical cabinet. The data link solution has also improved the installation’s long-term reliability and provided a seamless transition when switching from sequencer to local control in the event the sequencer is powered off.
    • Created system harmony by synchronizing all compressors – regardless of compressor type and size.
    • Took the system’s pressure below the 10-psi band.
    • Reduced kW/100 cfm to only 19.8.
    Key Figures (Per Year)
    • Cost Savings

      $19,000

    Final Thoughts

    This installation presented several challenges. One of the biggest was that the incoming compressor would be located in a new building 650 feet away from the existing compressors and connected via an underground conduit. However, through harnessing Ethernet over a 2-wire solution, installation was seamless and worked flawlessly. Our SMART-TAG interfaces were key in this installation, too, as they facilitated the simple connection of the two variable speed machines, both of which used different controllers. Now that this system can be remotely monitored, it benefits both the end user and the distributor since the main compressor installation is located within a remote building.

    Spokesperson for AIRMATICSTM

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  • Food & Drink

    A global drinks manufacturer

    UK

    A Global Drinks Manufacturer
    • Four 3-stage compressors, all of which were different sizes, were set to run at pre-programmed periods – with manual intervention being the only way to alter run times.
    • Incorrect compressor combination running at the wrong times was repeatedly resulting in high levels of unproductive power and poor energy efficiency.
    • Storage was significantly under capacity, which was contributing to system volatility and further energy inefficiency.
    • Lack of system visibility beyond the plant room and no understanding of power or flow levels – and therefore system efficiency.
    • AIRMATICSTM was installed, which: Facilitated dynamic compressor selection, effectively matching the correct level of compressed air with factory demand;
    • Provided full and real-time visibility of power, flow and dew point levels in both the plant room and AIRCLOUD, where data is stored and can be accessed and analysed from anywhere via any device;
    • Additionally, air receivers were installed to increase the stored volume, which reduced system volatility and rapid loading and unloading of the compressors.
    • Saved the manufacturer £72,235 a year in energy bills.
    • Cut energy usage by 555,654 kWh.
    • Reduced CO2 by 148,174 kg.
    Key Figures (Per Year)
    • Energy Savings

      555,654 kWh

    • Cost Savings

      £72,235

    • CO2 Savings

      148,174 kg

    Final Thoughts

    This particular manufacturer, which produces many of the world’s most well-known drinks, has a plan to be as carbon-friendly as they possibly can be by 2025 and have set aside a sustainability budget to achieve this goal. We’re proud to have contributed towards their plan and played a role in helping them to achieve their sustainability targets.

    Spokesperson for AIRMATICSTM

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  • Packaging

    Advance Packaging

    USA

    Advance Packaging
    • The customer was using three different controllers of different ages and capability to control one installation.
    • The system was experiencing off-shift demand swings, which was causing erratic plant pressure. When pressure dropped, someone would turn on more compressors than needed just to get plant pressure in a safe range. This resulted in high and unnecessary energy usage.
    • There was no dew point accountability, which meant packaging machines often required unscheduled maintenance and caused downtime due to high levels of condensation at the points of use.
    • AIRMATICSTM was installed, which: Included the AERO Sequencer, allowing the customer to control five compressors of varying ages and capacity with one single controller and deliver remote asset monitoring;
    • Saw our SMART-TAGs provide an easy-to-use and unified interface between the controllers;
    • Featured dew point sensor technology in order to provide greater accountability and support the customer’s requirement for weekly reporting of its assets.
    • Enabled the customer to control five compressors of varying ages and capacity with one single controller, and delivered remote asset monitoring.
    • Reduced kW/100cfm to only 19.5.
    • Delivered ROI in less than two years.
    Final Thoughts

    The distributor, TMI Compressed Air Systems Inc., has been a proven leader in air tag remote monitoring devices for several years. This project was the first AERO installation for them – and it was also the first installation to use StarTag data link connections to the Sullair Supervisor, WS and STS controllers. The AERO is performing really well. The pressure band reduction alone is delivering energy savings of around 6-7 percent, and whilst this was a good performing system prior to the installation of AIRMATICSTM, it’s now a great performing system, providing the reporting both TMI and the end user were looking for.

    Spokesperson for AIRMATICSTM

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  • Food & Drink

    A prominent national water bottling manufacturer

    Greece

    Vikos Greece
    • The customer had in place five high pressure compressors with a total of 1,200 kW installed power that it wanted to manage smartly using the latest technology.
    • Unloaded power across the compressors was running high.
    • There were significant – and random – drops in pressure across the entire compressed air network.
    • AIRMATICSTM was installed, which allowed the customer to manage all their compressors through one state-of-the-art control platform;
    • Utilised AERO – the AIRMATICSTM control unit – and its unique Pressure Balance feature, which eliminated the random drops of air pressure the customer was experiencing;
    • Reduced overall pressure levels across the customer’s compressed air network.
    • Save €58,000 a year on its energy bill.
    • Cut unloaded power levels by 20 per cent.
    • Reduce pressure levels by a total of 6 bar.
    • Achieve a payback on investment in less than 11 months.
    Key Figures (Per Year)
    • Energy Savings

      491,000 kWh

    • Cost Savings

      €58,000

    • CO2 Savings

      303,000 kg

    Final Thoughts

    Prior to CMC’s site visit, the customer was experiencing erratic loading and unloading of each compressor due to random – and often huge – pressure drops throughout its compressed air network. By installing CMC’s AIRMATICSTM solution, the customer was not only able to significantly reduce the impact of the system’s huge air demands, which originated from their blowers, but also eliminate the erratic start/stop of the compressors.

    Spokesperson for AIRMATICSTM

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  • Manufacturing

    An international engineering group

    UK

    Trelleborg
    • The customer had five compressors, all of which were manufactured by different brands and located in two different sites. With total installed power spanning 655 kW, it wanted to manage all five using one control solution.
    • Unloaded compressor power was running too high.
    • Pressure levels across the entire compressed air network were higher than necessary.
    • AIRMATICSTM was installed which facilitated the effective and harmonious control of the customer’s five air compressors;
    • Harnessed the system’s Zone Control feature, enabling the customer to take a multi-location approach to managing its compressors;
    • Saw the customer use the technology’s Pressure Balance feature, which cut pressure drops from the system.
    • Reduce its compressed air energy bill by over €24,000.
    • Decrease unloaded power by 90 percent.
    • Cut pressure levels by 1.3 bar.
    • Achieve a payback on its investment within 10 months.
    Key Figures (Per Year)
    • Energy Savings

      322,000 kWh

    • Cost Savings

      €24,000

    • CO2 Savings

      198,000 kg

    Final Thoughts

    Trelleborg’s inability to accurately match compressed air production to compressed air demand, due to not having a suitable system management solution, meant that it wasn’t operating anywhere near as efficiently as it could be. However, after installing a CMC management system, the customer was able to utilise a series of features that not only remedied this issue in the short-term, but in the long-term, too.

    Spokesperson for AIRMATICSTM

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  • Food & Drink

    An international cheese and dairy producer

    France

    Dairy Producer
    • The customer had three Ingersoll Rand compressors spanning 400kW of installed power that it wanted to manage and synchronise using the latest IoT technology.
    • Unloaded power was running high.
    • The compressed air system was continually experiencing severe and unplanned pressure drops.
    • AIRMATICSTM was installed, which: ensured that the three operational compressors were working together effectively;
    • Enabled the customer to harness the Pressure Balance feature of the Metacentre XC and prevent unplanned pressure drops;
    • Reduced the unloaded power consumption of all three compressors.
    • Cut more than €14,000 a year from its energy bill.
    • Reduce unloaded power by 90 percent.
    • Decrease system pressure levels by 0.9 bar.
    • Achieve payback on investment in less than 10 months.
    Key Figures (Per Year)
    • Energy Savings

      175,000 kWh

    • Cost Savings

      €14,000

    • CO2 Savings

      108,000kg

    Final Thoughts

    Due to an absence of smart technology and ongoing problems with pressure drops, the customer couldn’t correctly manage its compressed air system and effectively match compressed air production with compressed air demand. Through installing AIRMATICSTM, it was able to get more from its compressed air system, save money and drastically drop pressure levels across its compressed air network.

    Spokesperson for AIRMATICSTM

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