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Compressed Air System Upgrade for D’Orsogna
D’Orsogna approached Nessco Pressure Systems with concerns about compressed air quality, pressure loss and energy use at its Perth food manufacturing facility.
Compressed air plays an important role throughout the factory, so the system needed to provide reliable pressure and flow while meeting the different air quality requirements across the production process.
Before recommending new equipment, NPS started by looking at how the existing system was actually performing.
Starting with a compressed air audit
NPS completed a compressed air audit, mapping the existing distribution system and recording the operating patterns of the four compressors supplying the factory.
The results gave our team a clearer picture of compressed air demand and how the existing compressors were responding to changes in production.
We provided D’Orsogna with a detailed report outlining the findings and recommendations for improving the system.
Based on the recorded demand profile, NPS recommended replacing the four existing load/unload compressors with a 90 kW variable speed drive (VSD) compressor.
A VSD compressor adjusts its output as air demand changes. For a facility with varying demand, this can reduce unnecessary unloaded running and help the compressor respond more closely to production requirements.
Improving compressed air treatment
The new system included an oversized refrigerated dryer, pre-filtration and coalescing filtration, along with a 3,000 L air receiver.
NPS connected the equipment using Infinity aluminium compressed air pipework.
We also modified the existing distribution system to create a ring main. This helped improve compressed air distribution throughout the factory and provide more consistent pressure and flow at the required points of use.
Managing different air quality requirements
Not every application within a food manufacturing facility necessarily has the same compressed air quality requirements.
D’Orsogna had identified areas of production where a higher level of compressed air purity was required.
NPS worked with the D’Orsogna team to identify these points and installed a dedicated adsorption dryer and filtration system to provide additional air treatment where needed.
This allowed the compressed air treatment to be matched more closely to the requirements of different processes rather than applying the same level of treatment across the entire factory.
Managing condensate
Condensate management was another consideration during the system upgrade.
Compressed air condensate can contain oil from oil-injected compressors and shouldn’t simply be discharged untreated.
NPS incorporated an oil-water separator to process condensate collected from the dryer, air receiver and filters before disposal.
This also supported D’Orsogna’s broader focus on reducing the environmental impact of its operations.
Improving compressed air distribution throughout the factory
The project also included 35 new compressed air droppers across the facility.
These incorporated safety features including air fuses and hose support cables.
If a compressed air hose fails, an air fuse can restrict airflow and help reduce uncontrolled hose movement. The additional safety measures provided greater protection for people and equipment working around compressed air points throughout the factory.
A complete compressed air system upgrade
This project involved much more than replacing the existing compressors.
By first understanding how D’Orsogna was using compressed air, NPS could look at the complete system. This included generation, drying and filtration, storage, distribution, condensate management and point-of-use requirements.
The result was a compressed air system designed to provide the pressure, flow and air quality required across the factory while responding more efficiently to changes in compressed air demand.
“Nessco Pressure Systems was a pleasure to work with and were on time and on budget. The installation went really well and the project also fits perfectly with our sustainability agenda as saving energy is one of our top priorities. The compressors are working very efficiently and delivering a high specific output of clean quality air.”
– Neil Harvey, Chief Engineer
Nessco Pressure Systems provides compressed air audits, system upgrades, installations and ongoing servicing for manufacturing facilities across Perth and regional WA.
If you are experiencing pressure problems, increasing energy use or changes in compressed air demand, call our team on 1300 290 638 to discuss your system or email us to arrange a chat with one of our compressed air specialists.
