Compressed Air Reduction

Contribution to sustainable development and people’s quality of life:

Reduced energy use lowers the cost of manufacturing making Metzeler more competitive in today's global market, whilst ensuring that Metzeler are a social and environmentally responsible employer.

Organisation: Metzeler Automotive Profile Sealing Systems

Sector: Private

Location: Leicestershire / North West Leicestershire / Coalville

Start Date: March 2004

Duration: 5 months

Summary: Metzeler manufacture rubber sealing systems for car windows and doors. The process uses compressed air as part of the extrusion process. This is an energy intensive process and the aim of the project is to lower the energy bill by reducing the use and misuse of compressed air.

A further aim is to eliminate the need to purchase an extra compressor which would be required as the demand is at 98% of the capacity.

Background: The capacity for air generation at Metzeler is 3000 Cubic Feet per Minute (CFM). The peak demand in April 2004 was 3060 CFM. In order to understand where this air was being used a survey of the site was undertaken. This highlighted that up to 40% of the air was being used for processes that are classed as misuse in the Energy Efficiency Best Practice Publications. Members of staff were also engaged in the process and many have made useful suggestions for savings. Their role will become even more important as bigger savings are to be made.

Project results: After work in the factory the average air demand has dropped by 800 CFM and the peak demand by over 100 CFM. This represents a saving of approximately £44,500 per annum. We have also identified further savings which will be realised in phase 2 of the project. We now have the equivalent of two spare compressors thus eliminating the need to buy new ones (compressors cost around £30,000 each).

A further benefit is that the background noise in the factory has been reduced, improving conditions for staff.

Keywords: Compressed Air / Energy Reduction

Contact Details:

Martin Dinsley
Process Improvement Engineer

Tel: 01530 816201
E-mail: martin.dinsley@maps-eu.com