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Case Studies

World leading drinks company

Kerr's Solution

Having primarily been a Compair customer for over 30 Years, when one of the World’s Leading Drinks Companies decided to install New Kaeser/HPC Compressed Air Equipment, it was safe in the knowledge that they were getting a quality product with a guaranteed service back-up.

Having tried Kaeser/HPC Equipment at a previous site for over 10 years, including at that time the installation of a purpose built compressor house, operating on a 24/7 basis ever since, and looked after by Kerr’s engineers, this made the decision to move away from Compair an easier choice.

Having evaluated the specification issued, we proposed to supply 2 Off 90 kW Energy Efficient Kaeser/HPC Variable Frequency Drive ‘Dry Screw’ Air Compressors, Model CSG130-2A SFC. The units are 100% Duty/Standby operation, each providing up-to 465 cfm @ 10 Bar Working Pressure. Fully controlled and remotely monitored by a Kaeser/HPC Sigma Air Manager 3D, the customer can ensure that his system is continuously maintained by Kerr’s engineers.

To further ensure the air quality was maintained to the specification expected of a major drinks company, we installed 2 Off Parker MXLE104 D/S Desiccant Air Dryers c/w Evolution Filtration. Again these operate on a Duty/Standby basis.

Due to on-site space constraints, all of the equipment had to be housed in a purpose built compressor house. This was also carried out by Kerr’s providing a GRP Enclosure fully installed with all lighting, electrics, ventilation and ducting requirements. All the customer had to do was provide the space and install the mains cable to our Distribution Board.

The Outcome

Completing the installation was a fixed price maintenance contract covering all parts and labour and ensuring the equipment retains its manufacturers provided ‘Lifetime Warranty’.

Energy efficient nitrogen production

The Challenge

Requirement for constant supply of Nitrogen to operate laser cutting machine. Currently using bottled Nitrogen which requires bottle to be changed over when empty and also operational overhead of arranging delivery to ensure constant supply.

Kerr's Solution

After taking the details of the proposed new Laser Cutting machine he was having installed, we formulated a proposal to provide the Nitrogen through his own in-house Nitrogen Generator.

The savings that the customer could make including all supply, maintenance and operational costs easily outweighed the cost of buying the bottles, plus the inconvenience of changing them over every time they emptied. Paybacks of less than 3 Years were possible on his proposed production schedule, with the opportunity to improve if his production increased.

As an existing HPC/Kaeser user with 7 other models within his group of companies and over 15 Years of HPC/Kaeser reliability with Kerr’s providing all his service requirements, it was an easy choice to select the same again.

The Outcome

Equipment supplied was a New HPC BSD75 SFC (37 kW Variable Frequency Drive Compressor c/w the latest IE4 Electric Drive Motor), Parker Domnick Hunter Desiccant Dryers, Filtration & Maxi-Gas N2 Generator, Bauer MVG12.2 7 Bar-300 Bar Booster Compressor & High Pressure Storage Bottles.

With this set-up our customer now has the facility to operate his full production cycle, whilst re-charging the storage bottles during the night for the next day, therefore he never runs out. Nitrogen is provided at 20 Bar with a purity of 99.999% N2.

All equipment comes with a Full Five Years Parts & Labour No Quibble Warranty.

Air quality improvement at bolting plant

The Challenge

Barr’s is one of the major soft drinks suppliers in Scotland and the UK, with their own unique brands of soft drinks.

At the Cumbernauld facility they have four Bellis & Morcom high pressure compressors that provide compressed air at 40 Bar for blowing the bottles on the PET moulding lines.

The compressed air was being treated via air cooled Denco refrigerant dryer equipment which had been installed back in the mid 1990`s, the condensate removed by the dryers was controlled using timed solenoid drains as opposed to zero loss drains.

In today`s climate the gases used within the refrigerant circuits of these Denco dryers are not the most environmentally friendly and also due to the age of the units the maintenance costs were becoming more and more expensive as well as starting to have a detrimental effect on production.

Kerr's Solution

Our design team sat down with the project`s engineer from Barr`s and after several meetings and detailed discussions a proposal was submitted to install two new energy efficient BEKO high pressure dryers complete with zero loss drains, these dryers also have the most up to date environmental refrigerant gases in today`s market.

One of the other reasons for the Barr`s group choosing Kerr Compressors was the fact that we could offer a complete turnkey package in regards to the installation of the new equipment for both the mechanical and electrical requirements due to the fact that we carry our own coded welders for the pipework and certified electricians.

This proposal that was submitted, satisfied the clients requirements and concerns by providing 100% standby capacity availability for production purposes, the dryers complete with the zero loss drains provided the most energy efficient solution in regards to compressed air wastage and at the same time assisted with their environmental impacts which is a major concern to the client to achieve continuous improvement.

Another benefit for the client was the reduction of maintenance costs for controlling the air quality within the compressed air system by less failures and expensive repairs.

The Outcome

Since the completion of the installation, the new dryers have provided Barr`s with overall improved system reliability, a more energy efficient package due to the management of the discharge of the condensate and the fact that the compressors are no longer running to deal with wastage air but that of the actual demand requirement of the facility.

Norbord

The Challenge

Installation of compressed air system in Mill

Kerr's Solution

The Kaeser DSD 238 Rotary Screw compressor is a high performance and high efficiency compressor for industrial compressed air stations.

These high performance systems help save energy in various ways:

  • Flow-optimised SIGMA PROFILE rotors improve specific power.
  • The use of IE3 drive motors maximises energy efficiency (these motors will become mandatory in the EU from the 1st of January 2015).
  • Kaeser's 1:1 drive design eliminates the transmission losses associated with gear or V-belt driven systems, as the motor directly drives the airend.
  • The SIGMA CONTROL 2 compressor controller optimises performance by using specially developed control algorithms.

The Outcome

The compressed air system was installed to customer specification and on schedule.

Customer Testimonial:

“Kerrs compressors supplied our mill with a kaeser dsd 238 unit, and from purchase to installation and onto the routine servicing of the compressor there professionalism was faultless. I would highly recommend them for all your compressor needs and we would definitely be using their services for future projects and general maintenance.”

Main Tool

The Challenge

Replacement of an ageing, inefficient and unreliable Ingersoll Rand Compressor with a modern solution.

Kerr's Solution

After considering the options we offered the HPC ASK32 c/w TCH32 Air Dryer and Filtration.

The Outcome

The compressed air system was installed to customer specification and on schedule.

Customer Testimonial:

“Main Tool needed a new compressor with a reliable company, so after searching around and getting several major compressor companies to give me their schedule, Kerr's was the best option with a good machine, at a reasonable cost and offered the best back up service around with an upfront service package of choice. I've never been let down with any of their service, which is more than I can say for one of the main competitors who we had been using for 30years before, so I did not take the decision lightly when using them, but it was the best decision MTC made.”

To find out more get in touch:

East Kilbride: 01355 248 222

Perth: 01738 629 220
Aberdeen: 01224 772 992
Inverness: 01463 715 234

 

enquiries@kerrcompressors.co.uk