CompAir’s Quantima cuts carbon and servicing costs for MGC

CompAir’s Quantima compressor system has helped Australia’s largest milk processor, Murray Goulburn (MGC), reduce costs and carbon emissions.

MGC has in place a continuous development program to reduce its carbon footprint. This program, in conjunction with the availability of Sstate funding towards the purchase of energy-efficient technologies, prompted MGC’s Group Maintenance Manager, Mark Gurney, to consider replacement options for the existing compressed air system at the company’s Leongatha plant in Victoria.

CompAir's Quantima compressor system.

The company required a complete new system to supply all of the factory’s compressed air requirements for both plant and packaging processes, including new compressor units, air supply pipes and dryers.

CompAir Australasia put forward a proposal for the new system that involved replacing the four existing compressor units with just one 300 kW Quantima compressor and leaving two units for standby air. The new system was commissioned successfully in November 2007.

A detailed audit was taken before and after the installation, proving without a doubt that the new installation has enabled MGC to meet its power reduction target with an overall energy saving of more than 35%.

“By combining the innovative Quantima compressor with all downstream equipment, including desiccant dryers and new air distribution pipes, we have been able to reduce pressure drops and air leaks dramatically,” said Gurney.

“Prior to the installation, our compressed air system was using 9.1 kW to generate each cubic metre of air per minute. Now, with Quantima, this specific power consumption has reduced significantly to just 6.12 kW/Nm³/min. In simple terms, we are now producing compressed air at best practice levels and with much better efficiency - to the effect it is now taking 33% less power for us to generate a higher air output.”

MGC has already realised CO₂ savings of 1908 tonnes - equivalent to planting over 2805 trees or taking 440 cars off the road.

The Quantima saves energy through its Q-drive, a centrifugal compression assembly that consumes significantly less power than conventional technologies. Q-drive’s rotor shaft is its only moving part, reducing friction contact that can result in energy losses and performance degradation over time. A variable speed drive allocates airflow according to plant demand to further save energy.

The Quantima has not only saved MGC energy; its predictive maintenance solution, Q-life, also saves on servicing costs. CompAir engineers monitor the machine’s performance remotely, moderating it where necessary to prevent a fault occurring or arranging a local engineer for remedial repairs.

CompAir had already been providing regular servicing to MGC’s plant, carried out by local CompAir engineers. Q-life also comes with risk-free, fixed price servicing, a solution which has saved MGC 64% on its service costs. Another bonus is that Quantima’s oil-less system negates the need for disposal and treatment of waste oil and condensate - and all the associated costs.

MGC and CompAir are working together to design water-cooling towers to reduce the plant’s energy consumption further. The towers are projected to save another 71 kW of installed power, meaning a further 677 tonnes of CO₂ savings each year.

Gurney is happy with the new system: “Instead of simply replacing one or two of our existing compressors, we chose to install a complete new system that would deliver a low cost of ownership, with the maximum energy savings possible. We are very pleased with the results.

“After only five months, the Quantima compressor has already delivered the energy-saving and carbon footprint reductions that we expected. Overall the project will pay back, pre tax, in 22 months.”