Food Manufacturing Compressed Air System for Quaker Oats
Quaker Oats Australia is a leading Australian manufacturer and supplier of oat products for human consumption.
As production requirements increased, Quaker Oats needed a new compressed air system that could support the immediate expansion while providing additional capacity for future growth.
Nessco Pressure Systems assessed the site and designed a complete compressed air solution around the required flow, pressure, air quality and production requirements.
The challenge
The new system needed to deliver at least 840 CFM at 10 bar while allowing for further expansion of the production line.
Quaker Oats also required:
- Capacity for future production growth
- Clean, dry compressed air
- Food-grade compressor lubricant
- Lower operating costs
- Reliable equipment backed by ongoing servicing and warranty support
Rather than sizing the equipment around the immediate expansion alone, NPS considered how the compressed air requirements could change as production increased.
Assessing the compressed air requirements
NPS completed a site audit to understand the existing system, production requirements and areas that needed attention.
Our team then assessed the required flow at 10 bar and selected two 75 kW compressor systems to meet the site’s compressed air demand.
The system design also considered future production requirements so Quaker Oats could add equipment without immediately outgrowing the new compressed air capacity.
Matching compressor output with changing demand
NPS selected variable speed drive compressors as part of the solution.
Production demand doesn’t always remain constant. VSD technology allows a compressor to adjust its output as compressed air demand changes, rather than continually producing its full rated capacity.
For this application, the VSD compressors provided a practical way to support changing demand while helping control unnecessary energy use.
Managing compressed air quality
Air quality formed an important part of the system design.
NPS incorporated industrial inline filtration and refrigerated air dryers to manage moisture and contaminants within the compressed air supply.
The compressors also used food-grade lubricant as required for the application.
Compressed air requirements can vary across food manufacturing processes, so NPS selected the air treatment around the requirements of the site rather than applying a standard treatment package.
Managing condensate
Compressors and air treatment equipment produce condensate as moisture is removed from the compressed air system.
Where oil-injected compressors are used, this condensate can contain traces of compressor oil and requires appropriate treatment before disposal.
NPS incorporated an oil-water separator into the system to separate oil from the condensate and support appropriate condensate management.
A complete turnkey installation
NPS managed the project as a turnkey compressed air installation.
The scope included:
- Selection and supply of the two 75 kW compressor systems
- Coordination of equipment supply with the planned shutdown
- Electrical and mechanical connections
- Industrial inline filtration
- Refrigerated air dryers
- Oil-water separation
- Remote start/stop connectivity
- PLE reporting
- Commissioning
- Operator training
NPS also provided a 10-year warranty arrangement supported by an ongoing servicing agreement.
Supporting current and future production
The completed food manufacturing compressed air system provided Quaker Oats with the required 840 CFM at 10 bar, while allowing capacity for planned production growth.
By considering compressor capacity, changing demand, air treatment, condensate management and future requirements as part of the same project, NPS delivered a system designed around the site’s production needs rather than simply replacing individual pieces of equipment.
Nessco Pressure Systems designs, installs, commissions and services compressed air systems for food and beverage manufacturers and other industrial facilities across Perth and regional WA.
From compressors and dryers to filtration, receivers, condensate treatment and pipework, our team can provide a complete compressed air solution based on your required flow, pressure, air quality and application.
To discuss your compressed air requirements, call our team on 1300 290 638 or contact us online.
