PCM AIRPOWER recently completed a compressed air system upgrade for BIOPAX in Belfast, delivering significant energy savings while supporting the company’s ongoing commitment to sustainable manufacturing.
The Challenge
Following a comprehensive data logging exercise carried out by the PCM AIRPOWER team, BIOPAX’s existing BOGE 30kW fixed-speed compressor was monitored to better understand site demand and operating efficiency.
The results highlighted a significant number of unloaded running hours. While the compressor was still consuming power, it was producing little useful compressed air, resulting in unnecessary energy consumption and increased operating costs.
For many manufacturing facilities, compressed air is one of the most expensive utilities on site, making system efficiency a key opportunity for cost reduction and sustainability improvements.
The Solution
After analysing the data, PCM AIRPOWER recommended upgrading the existing compressor to a modern Variable Speed Drive (VSD) model.
BIOPAX subsequently invested in a new BOGE 30kW VSD compressor, which was supplied, installed and commissioned by the PCM AIRPOWER engineering team.
The installation included:
- BOGE SLF 40-3 Variable Speed Compressor
- Air Receiver and Filtration Equipment
- Full Installation and Commissioning
- System Optimisation Based on Data Logging Results
Unlike fixed-speed compressors, VSD technology automatically adjusts compressor output to match demand, reducing energy waste during periods of lower compressed air consumption.
The Results
The benefits of the upgrade were immediately evident following commissioning.
The new compressor is currently operating efficiently within a load profile of approximately 55% to 75%, closely matching site demand and significantly reducing wasted energy.
Based on the site’s operating hours, estimated savings include:
- Annual Energy Savings: Approximately 38,064 kWh
- Annual Cost Savings: Approximately £11,419
- Reduced Unloaded Running Time
- Improved System Efficiency
- Lower Environmental Impact
The BIOPAX team has been delighted with the immediate improvements in performance and energy efficiency.
Supporting Sustainable Manufacturing
As a company focused on environmentally responsible manufacturing, BIOPAX continues to explore opportunities to further reduce energy consumption and improve sustainability across its operations.
PCM AIRPOWER is currently investigating the potential installation of a BOGE DUOTHERM heat recovery system. This technology allows waste heat generated by the compressor to be recovered and reused elsewhere on site.
By reclaiming thermal energy from the compressor’s hot oil circuit, BIOPAX could potentially heat water for hand-wash facilities and other applications, reducing reliance on traditional gas or electric water heating systems.
A Data-Driven Approach to Compressed Air Efficiency
This project demonstrates the value of combining detailed system analysis with modern compressed air technology.
Rather than simply replacing equipment, PCM AIRPOWER used real operating data to identify inefficiencies, recommend the most appropriate solution and deliver measurable results for the customer.
If your business is experiencing rising energy costs or you would like to understand how efficiently your compressed air system is operating, PCM AIRPOWER can provide data logging, energy audits, system optimisation and complete compressed air installations across Northern Ireland and Scotland.
Contact our team today to discuss how we can help improve the performance and efficiency of your compressed air system.
We are fully BCAS compliant.
