Compressed air recovery system installation from process machine

Installation of a compressed air recovery system from a process machine

The implementation of a compressed air recovery system in a plastics production plant reduced energy losses and lowered costs by more than PLN 230,000 per year. The payback period was less than 1.5 years.

Context

The production of plastic components on stretch blow molding machines is highly energy-intensive. It requires the use of compressed air at very high pressure (30–36 bar), the generation of which incurs significant electricity costs. In the standard system, this air, after the production cycle ended, was released directly into the atmosphere – even though it still retained considerable residual pressure.

The challenge

The key problem turned out to be the loss of large amounts of energy in the form of unused compressed air. For the plant, this meant not only high costs but also inefficient management of energy resources in the production process.

Our approach

Already at the stage of the energy audit, we identified the area with the greatest cost reduction potential – compressed air losses after the blow molding cycle. It was crucial to thoroughly analyze the energy balance of the compressors and the parameters of the forming process. We then developed a recovery concept that combined the technical capabilities of the installation with the plant’s actual demand.

The implementation was carried out without disrupting production – using the existing infrastructure and adapting the recovery system to the low-pressure network. This approach made it possible to achieve technical and financial synergy: minimal air losses, lower energy consumption, and a quick payback period.

Solution

The energy audit revealed the possibility of installing a compressed air recovery system, thanks to which this medium could be reused. The following were implemented, among others:

air recovery system – allowing air after the blow molding cycle to be directed to the lower-pressure network,
integration with existing infrastructure – so that the recovered air could support other production processes, reducing compressor operation,
air balance optimization – ensuring the stability and safety of the entire process.

Thanks to this, air with still useful residual pressure was utilized instead of being wasted.

Results

The actions implemented by DB Energy resulted in:

reduction of low-pressure network air production by 29%,
financial savings of PLN 232,310 per year,
a payback period of less than 1.5 years,
improved process energy efficiency and reduced system losses.

Conclusions

The implementation of the compressed air recovery project demonstrated that even in such an energy-intensive area as plastics blow molding processes, it is possible to find relatively simple and highly profitable improvements.

Thanks to the analysis of the energy balance, we were able to use air with residual pressure that had previously been irretrievably lost. This translated into a 29% reduction in energy consumption in the low-pressure network. A payback period of less than 1.5 years confirmed the high economic attractiveness of the investment, with the additional benefit of improved stability and reliability of production processes.

This project confirms that activities in the area of technical media – such as compressed air – can be an important lever of energy efficiency and significantly strengthen the competitiveness of industrial plants.

Nasze najnowsze realizacje, które Cię zainteresują

The largest LNG-powered cogeneration unit in southern Poland – Schumacher Packaging Myszków

The largest LNG-powered cogeneration unit in southern Poland is now operating at Schumacher Packaging in Myszków. Thanks to an investment of 21.8 million PLN, the facility has achieved nearly 80% energy independence, producing almost 9 MW of electricity and significant amounts of heat. The project, implemented by DB Energy, demonstrates how an energy audit can serve as a starting point for a comprehensive energy transformation of a factory – from modernization of existing heat sources, through energy recovery, to the implementation of advanced cogeneration.

Przejdź do artykułu

Higher production and lower emissions – a chemical industry client on the path to net zero

At a chemical plant in southern China, we developed a 4-month strategy to reduce emissions by 70%, enabling increased production while lowering energy consumption and laying the groundwork for achieving net zero by 2035.

Przejdź do artykułu

Zero-emission in practice – emission reduction in pharmaceutical chemistry

Zero-emission in the chemical industry is not theory but concrete action. For a client in the pharmaceutical sector, we prepared a CO₂ reduction roadmap and implemented an incinerator modernization with heat recovery. The result? 12 GWh of thermal energy saved, a reduction of 2,172 tCO₂, and a quick payback period.

Przejdź do artykułu