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What Are the Advantages of Using Blower-Driven Air Compared to Compressed Air?

The Shift from Compressed Air to Blower-Driven Systems Drying plays…

What Are the Advantages of Using Blower-Driven Air Compared to Compressed Air?

The Shift from Compressed Air to Blower-Driven Systems

Drying plays a crucial role in the food and beverage industry because of how it helps maintain product quality and safety. Compressed air systems have long been the go-to choice for this purpose. However, a  shift is underway, with blower-driven air knife systems rapidly gaining prominence. But what advantages does blower-driven air have over compressed air?

Blower-driven air systems have several advantages over compressed air. They are more energy-efficient and can be easily controlled via Variable Speed Drive. Compressors take up more space, so air knife blowers are more space-efficient and less costly than installing and maintaining compressors.

By replacing their compressed air-based drying systems with blower systems like air knife blowers, industries can revolutionise how they dry their food and beverage containers. There is an extensive list of advantages and benefits, so let’s examine how your business can benefit from installing a blower-driven air system.

 

Understanding Blower-Driven Air Systems

Blower-driven air systems represent a departure from traditional compressed air systems on several levels.

First, they are specifically designed for drying applications, so their streamlined design optimises performance while minimising energy consumption.

Unlike compressors, which rely on energy-intensive processes, blower systems utilise impellers or centrifugal fans to generate high-velocity air to create airflow. They are equipped with Variable Speed Drives (VSD) to allow precise control over the airflow and pressure, so manufacturers can adapt them to their various drying needs without compromising efficiency.

 

Advantages of Blower-Driven Air for Food and Beverage Manufacturing

Switching from compressed air to an air knife blower offers several advantages in industrial applications. Let’s examine these benefits.

Energy Efficiency

Blower-driven systems consume far less energy than traditional compressed air systems, which can translate to significant cost savings for food  and beverage producers.

Air knife blowers, in particular, can play a crucial role in energy efficiency. These systems use high-powered blowers to generate clean, oil-free, and moisture-free air. By eliminating the need for energy-intensive compressors, air knife blowers ensure food and beverage safety while contributing to sustainable practices and lowering manufacturing costs.

Control and Versatility with Variable Speed Drives (VSD)

A question people often ask is if air blower systems offer the same level of control as compressors, but the truth is that they offer even greater control. The Variable Speed Drives (VSD) allow precise control over airflow and pressure in blower-driven systems.

By extension, this leads to more versatile applications. The VSD makes it easy to adapt the air blower system to your varying drying needs without compromising efficiency.

Eliminating the Need for Costly Compressors

Blower-driven air systems lead to considerable cost savings. They eliminate the need to purchase, maintain, and regularly replace costly compressors, thus freeing up resources for other critical investments in your production.

Furthermore, since air knife blowers are more energy-efficient than compressors, they contribute to an overall cost reduction by minimising operational expenses.

 Space Savings

Space efficiency is becoming increasingly crucial in modern compact and streamlined beverage and food production environments. Blower-driven systems occupy less floor space than bulky compressors, thereby optimising your production layouts.

 

Case Studies: Success Stories in the Food and Beverage Industry

Nobody needs an introduction to Coca-Cola, do they? The company is the largest soft drink manufacturer in the world, with over 900 production facilities. This giant corporation approached Secomak with one goal in mind: to help save energy at their Northern Ireland site, specifically by replacing their compressed air system with Secomak’s energy-efficient blower-driven system.

Secomak’s engineers travelled to Ireland to research the production requirements and statistics. The facility operated around the clock, seven days a week, to supply the necessary quantities. This amounted to an energy bill of around £54,000 per year, on one production line! Given the current economic landscape and the effects of climate change, it is critical for businesses to reduce their energy consumption.

Secomak proceeded to install the DryGuide system to replace the compressors, and the results were astounding. This Coca-Cola facility reduced its energy costs by more than £30,000 annually on only one line!

This is not entirely surprising, considering the amount of air consumed during the drying process and the cost of powering a compressor system. Secomak’s DryGuide uses a fraction of the power and delivers even better results, making it a more efficient system overall, as Coca-Cola experienced firsthand!

 

For more information contact our sales team at:

+44 (0) 208 732 1300, or email us at sales@secomak.com.

We’re here to help you choose the perfect drying solution for your business.

 

Financial Implications: Cost Analysis of Blower-Driven vs. Compressed Air

Let’s look at an example cost analysis by comparing Coca-Cola’s production costs using compressed air vs. DryGuide

The product is Coca-Cola 1.5 and 2 litre PET bottles. They are filled and wet, and the maximum production rate is 26,500 bottles per hour, running 24 hours a day, seven days a week.

 

Compressed Air System

Nozzles   Assumption
Number of nozzles (standard) 7 Each nozzle = 16 scfm
Number of nozzles (pt) 3 Each nozzle = 10 scfm
Total flow (standard cubic feet per minute) 142
Total power consumption in (kW) 28.4 1 scfm = 0.20 kW
Total power consumption (kWh) 248,926 1 year = 8765 hours
Total power cost in Pounds (running 8765 hours p.a.) £54,763.72 1 kWh = 22 pence

 

 

Secomak DryGuide 15

Drying Fixtures   Assumption
Number of fixtures 4 Each fixture = 400 m3/hr
Total flow (m3/hr) 1,600
Total power consumption (kW) 11 1 m3/hr = 0.007 kW
Total power consumption (kWh) 96,415 1 year = 8765 hours
Total power cost in Pounds (running 8765 hours p.a.) £21,211.30

 

Comparing the numbers in this typical, real-life example, we can see that Secomak’s DryGuide led to a cost reduction of £33,552.42 in just one year, and on only one line! These numbers should speak for themselves and give you a good indication of how much you could save on your drying.

 

Sustainability and Environmental Impact

Blower-driven systems can significantly reduce energy consumption compared to traditional compressed air systems. Manufacturers are increasing their bottom line by minimising energy waste while contributing to overall energy efficiency and environmental conservation.

Blower-driven air systems emit fewer greenhouse gases, thereby aligning with your company’s sustainability goals. Reduced energy usage also translates to less strain on natural resources, which benefits both the company and the environment.

Another factor that’s not always considered is that air knife systems are more efficient at drying food and beverage packaging. Efficient drying prevents product spoilage due to excess moisture, thereby reducing waste and benefiting the environment even more.

Aligning with Industry Trends

Lowering environmental impact is crucial since we need to conserve valuable natural resources, but there are also direct implications for the company itself.

  • Regulatory compliance: As environmental regulations tighten, adopting sustainable practices becomes essential. It is no longer just about being good for the environment but also complying with legal regulations. Blower-driven systems can be a crucial component in helping manufacturers meet these compliance requirements.
  • Corporate responsibility: There’s an increasing drive among consumers to support businesses that take their corporate responsibility seriously. Companies that are committed to caring for the environment tend to choose blower-driven technology as part of their responsible business practices.

In other words, blower-driven air systems offer a greener alternative for drying applications. By embracing these innovations, food and beverage manufacturers contribute to a more sustainable and eco-friendly industry while also complying with environmental regulations and proving their commitment to corporate responsibility.

 Implementation Guide for Blower-Driven Systems

Secomak’s engineers are trained to manage this process from start to finish, so reach out to find out how we can help.

FAQs on Switching to Blower-Driven Air Systems

Will air blowers deliver the same drying quality as compressed air?

Yes, if air blower systems are configured correctly, they can offer even better drying quality than air compressors due to the precision of air knife blowers.

Will an air blower system save me money?

Air blower systems are more energy-efficient than compressor systems, so they will lower your operational costs. Furthermore, purchasing and maintaining air blowers is far more affordable than compressors. Then there’s the fact that blowers contribute to your regulatory compliance, potentially saving you money on fines as well.

Are air blower systems hygienic enough?

Blower-driven air, including that from air knife blowers, meets stringent hygiene standards. It is clean, oil-free, and moisture-free, ensuring food safety.

Will the change lead to considerable downtime?

The downtime will depend on your business’s specific needs and requirements, but Secomak will help you plan the installation to minimise downtime and maximise efficiency.

Conclusion: Embracing Innovation for Efficiency and Sustainability

As we can see, blower-driven technology offers a compelling alternative to compressed air. Manufacturers that embrace this innovation will reap long-term benefits in energy efficiency, cost savings, and environmental res that completely justifies the replacement of current compressor-based systems through future ROI.

The process may seem complicated and time-consuming, but with Secomak, you will have nearly a century of experience behind you to make it seamless. So, take a look at Secomak’s industrial air blower systems and air knives to see how we can help you save costs, maintain regulatory compliance, and improve your efficiency.

 

 

 

 


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