Midland Plastics is one of the Midwest’s oldest and largest plastics suppliers with its headquarters in New Berlin, Wisconsin. They produce high-quality, custom plastic component parts utilizing advanced routing, machining, and milling technologies.

Whether the needs are dispensing head for food/beverage, a livestock/poultry feeder bin, or everything in between, Midland Plastics has a plastic solution that is lighter, more resistant, and longer lasting than traditionally used materials.

Midland’s in-house Engineering/Design capabilities, combined with complete manufacturing technologies, ensure they can bring to life any plastic need. Learn more about their capabilities, experience, and locations at https://midlandplastics.com/.

The Challenge

Midland’s existing vacuum pumps (Quincy QSVI-40 and (2) 40HP competitor fixed speed machines operating at 24”HgV) were being serviced by one of Quincy’s distributor’s, Zorn Compressor and Equipment. When the distributor asked how much vacuum they use, the customer replied “I don’t really know for sure. I think a second pump comes on sometimes”. That prompted the idea of conducting a vacuum audit to get an accurate assessment of what the process truly required.

Audit Results – The audit measured the vacuum level and motor amps over time. It was determined that their application required 553 ACFM @ 24”HgV, and was consuming approximately 44.25 HP to meet that demand.

The Solution

An evaluation of variable speed curves showed that a QSV 1100 E could meet the demand and consume approximately 17.5 HP less than the existing installation. Based on the customer’s cost of electricity and the annual operating hours, the solution represented a savings of nearly $9K in operating costs alone. For this end-customer, reducing the overall vacuum footprint was also of strong interest. Prior to the audit, a two pump solution (to provide redundancy) using larger pumps was presumed necessary. Excited to save energy and floorspace, the customer ordered the (2) QSV 1100E pumps AND an ECOntrol 3.0 (a multi-pump controller) to ensure the pumps are efficiently optimized as a central system!

With excellent coordination between Zorn Compressor and Equipment’s sales and service teams, the installation and commissioning yielded a beautiful, clean, and effective installation.

Key Takeaways

Auditing an existing installation is an extremely effective way to remove ambiguity, confirm/dispel preconceived notions of solutions, quantify savings, and provide clients with exactly what they need! If you suspect your vacuum system is underperforming, or curious to know if there’s a more efficient solution, Contact the Quincy Vacuum team today! Let the data guide the way!

Download Saving Energy and Operation Costs Case Study

Choose Quincy Compressor for Quality Compressed Air Systems and Solutions

Since 1920, Quincy Compressor has built an unparalleled reputation for innovative solutions and reliability in the most demanding industries and applications, including the following:

• Aerospace
• Amusement parks
• Automotive
• Brewing
• Climate control
• Dry cleaning
• Energy exploration
• Farming and agriculture
• Food and beverage
• Manufacturing
• Medical
• Mining
• Natural gas
• Oil and gas
• Painting
• Pharmaceutical
• Plastics
• Plumbing
• Textiles
• Woodworking

No matter your industry, we can provide your company with dependable, affordable air compressor systems and services. Click here to browse more of our case studies to discover how our innovative solutions have served customers and industries.

The post Saving Energy and Operation Costs appeared first on Quincy Compressor.

Founded in 1954, Olympic Steel is a metal services provider in the Mid-Atlantic and Northeast regions. Its operations in Milford, Connecticut, is a premier source for flat-rolled carbon steel, stainless steel and aluminum. Its full portfolio of metals includes the following and more:

• Cut-to-length
• Stretcher-leveled
• Temper-passed
• Burned-to-shape
• Formed
• Machined
• Painted
• Welded

Olympic Steel’s expansive geographic footprint allows it to excel in partnerships with national, multi-location accounts and regional customers alike. It has a manufacturing footprint of over 3.7 million square feet and over 30 facilities in North America.

The company is committed to providing national and regional original equipment manufacturers (OEMs), fabricators and service centers with quality materials and timely delivery. Its superior service is reflected in its extensive processing facilities network, outstanding sales and high customer satisfaction rankings.

Our team at Quincy Compressor performed an exhaustive study after Olympic Steel’s compressed air system faced some costly leaks. Read on to learn more about the challenges this leakage caused and our process for addressing them.

Why Is It Important to Address Air Compressor Leaks?

Many industries rely on compressed air systems daily, from breweries and dry cleaners to food and beverage processors. In fact, about 70% of manufacturers use air compressors. Compressed air is one of the most expensive yet essential utilities in many industries, using more energy than other equipment.

Leaks are a common issue facing air compressors, leading to expensive energy losses each year. They can significantly decrease system performance, causing a 25%-50% waste in total output and negatively affecting pressure settings. It only takes a small leak for your business to take a financial hit, leaking large amounts of air over time when left unresolved.

The Challenge

Olympic Steel had air compressors running at a higher capacity — an extra 20 horsepower, to be exact — to compensate for the audible leaks they were experiencing.

In Connecticut, the local utility company pays for 50% of the leak study. The state’s cost of power is incredibly high — $.28 per kilowatt hour. With the utility company paying for half of the leak study, Olympic Steel felt inclined to choose Quincy Compressor to perform the study.

The Action Plan

Our experts at Quincy Compressor performed a comprehensive leak study using a 124-microphone acoustic camera. This technology helps you detect leaks quickly, regardless of size. Because it allows you to scan a larger area, you can identify two leaks every five minutes.

The competitor’s solution involved one microphone leak detector, which requires the use of headphones due to hearing safety concerns. Additionally, the competitor’s technology requires manually scanning a small area, yielding only one leak every 20 minutes. Our Ultrasonic Leak Detection saved valuable customer time while addressing safety concerns.

Conclusion Highlights

At Quincy Compressor, we provide customers with more than parts and services. We also offer innovative digital solutions to optimize and reduce the costs of customers’ compressor operations.

Our team located a total of 49 leaks, equating to 79.40 cubic feet per minute of wasted flow each year. The leak study also saved $47,430 for Olympic Steel. We provided them with a comprehensive leak report, which gave them clear priority on what leaks to repair first based on their sizes and price estimations.

Air Compressor Leak Detection Solutions by Quincy Compressor

Did you know that air compressors lose an average of 20%-30% of compressed air due to leaks? This is a significant waste of money. A standard 200-horsepower installation with an air leak can waste up to $46,531.

Unfortunately, leaks are an unavoidable issue — every air compressor will experience one at some point. Numerous factors can contribute to leaking, such as poor pipe connections, weak seals and corrosion holes. Your air compressor could be hissing away money without your knowledge.

An air leak is expensive, but fortunately, Quincy Compressor can help you detect and repair it.

How Our Solutions Differ From Traditional Leak Detection Technology

We can perform a comprehensive air compressor leak study to help you avoid costly losses. Our acoustic imaging camera can identify leaks incredibly faster than conventional methods. A standard leak detector uses one microphone. Our camera uses 124 microphones to take measurements, letting you identify leak locations and determine priority based on size and cost estimation.

You can pinpoint smaller leaks due to the camera’s increased sensitivity and detection range (two leaks every five minutes). Additionally, you can locate leaks up to 426 feet away. Here are some other factors contributing to our industry-leading solution:

• Increased safety due to no soundproof headset requirements
• Real-time analytics for leak size and cost estimation
• Automatic report generation
• Minimal training to use the leak detection camera

Comprehensive Customer Leak Detection Reports

After you find the leak, repairing it may be as simple as tightening connections. Alternatively, it could require more substantial measures like replacing pipe sections, couplings, hoses, traps, joints, drains or fittings.

A leak audit provides a high-value report following the in-depth leak study. You can seamlessly create a professional customer-facing report once the audit is complete. This report summarizes the findings, clarifying actions that will yield the best results.

You can view each leak’s location on your facility’s site map. The report ranks leaks by the annual loss of cubic feet per minute and dollars. That way, you can easily determine which leaks require immediate action for optimal cost savings.

Choose Quincy Compressor for Quality Compressed Air Systems and Solutions

Since 1920, Quincy Compressor has built an unparalleled reputation for innovative solutions and reliability in the most demanding industries and applications, including the following:

• Aerospace
• Amusement parks
• Automotive
• Brewing
• Climate control
• Dry cleaning
• Energy exploration
• Farming and agriculture
• Food and beverage
• Manufacturing
• Medical
• Mining
• Natural gas
• Oil and gas
• Painting
• Pharmaceutical
• Plastics
• Plumbing
• Textiles
• Woodworking

No matter your industry, we can provide your company with dependable, affordable air compressor systems and services. Feel free to browse more of our case studies to discover how our innovative solutions have served customers and industries.

Contact a Quincy Representative for Air Compressor Leak Detection Services Today

In addition to our line of durable, efficient air compressor products designed for decades of use, we’re proud to provide industry-leading leak detection services for our customers. If you suspect an expensive leak in your air compressor system, you know who to call.

Additionally, we have a broad network of authorized distributors throughout the United States and worldwide. Your authorized dealer representative can guide you through the scheduling process and answer any questions you might have about the leak detection procedure.

Don’t let an air compressor leak cost you potentially thousands of dollars. Get in touch with our air experts for advanced leak detection and audit services. We invite you to find an authorized Quincy Compressor representative near you and schedule a leak audit today.

Download Case Study

View Quincy Compressor case studies

The post Olympic Steel – Air Compressor Leak Study appeared first on Quincy Compressor.

At Quincy Compressor, we are committed to delivering innovative solutions that empower businesses to achieve unmatched efficiency and performance. In this case study, we explore our successful collaboration with Bunge Oil, a renowned provider of specialty oils, milled grains and other ingredients to some of the world’s largest brands. With its extensive range of products, Bunge Oil plays a pivotal role in creating consumer and restaurant brands across the globe.

Recognizing Bunge Oil’s vital role in the food industry, we were eager to support their operations by addressing their unique challenges and optimizing their productivity.

Explore how Quincy Compressor helped revolutionize efficiency and performance for Bunge Oil, empowering them to continue providing high-quality ingredients and expertise to renowned consumer and restaurant brands worldwide.

The Challenge

With a rich history dating back to 1818, Bunge Oil has established itself as a leading producer of specialty oils. As a loyal customer of Quincy, Bunge Oil has relied on Quincy’s dependable QSI-235 compressor since 1983. The compressor has faithfully operated since then, supporting Bunge Oil’s critical operations.

However, Bunge Oil’s maintenance manager recently recognized the need for a new compressor. The existing unit started experiencing minor issues, causing concern for reliable operations. Moreover, relying on an equally aged backup unit during the primary unit’s downtime raised further apprehensions. Despite these valid concerns, the maintenance manager faced challenges in justifying the request for a new compressor to the corporate decision-makers.

Understanding the predicament Bunge Oil faced, Quincy proposed a solution: an EQ LTE audit. This audit had two primary objectives. First, it aimed to gain a comprehensive understanding of Bunge Oil’s plant operations, providing valuable insights into their energy consumption and efficiency. Second, the audit aimed to determine whether a compelling case could be made for investing in an energy-efficient solution, addressing the maintenance manager’s concerns and demonstrating the potential benefits of new equipment to the corporate decision-makers.

With this information, Quincy intended to build a solid business case to address the immediate need for a new compressor and highlight the long-term advantages of implementing an energy-efficient solution tailored to Bunge Oil’s specific requirements.

By highlighting the energy savings, improved reliability and enhanced operational efficiency that could be achieved with a modern compressor system, Quincy aspired to assist Bunge Oil in their pursuit of optimal performance and long-term sustainability.

“Quincy attached our EQ LTE data logger to Bunge Oil’s existing system and gathered information for one week. The data collected during the study was meticulously entered into Quincy’s specialized calculator, which our experts used to construct a compelling case tailored to Bunge Oil’s specific needs.” – Tom McCartney, Quincy Sales Engineer

Action Plan

Quincy attached our EQ LTE data logger to Bunge Oil’s existing system and gathered information for one week. This information facilitated an in-depth analysis of the plant’s data and energy consumption. This comprehensive study provided valuable insights into the intricacies of Bunge Oil’s operations, enabling Quincy to gather precise information for further evaluation.

The data collected during the study was meticulously entered into Quincy’s specialized calculator, which our experts used to construct a compelling case tailored to Bunge Oil’s specific needs. Through rigorous analysis and calculations, Quincy’s team determined Bunge Oil could realize significant cost savings by transitioning to a QGV-50 compressor.

By installing the energy-efficient QGV-50 compressor, Bunge Oil stood to achieve annual savings of over $8,000. These significant savings were primarily attributed to the enhanced energy efficiency and advanced features of the QGV-50, ensuring optimal performance while minimizing energy consumption.

Considering the cost of acquiring the new QGV-50 compressor, priced at $34,000, Quincy Compressor conducted a thorough return on investment (ROI) analysis for Bunge Oil. The calculations demonstrated that the investment in the QGV-50 would yield a positive ROI in slightly over four years.

Bunge Oil would recoup the initial investment in a relatively short time frame and enjoy substantial long-term financial benefits due to the improved energy efficiency and operational cost reductions offered by the QGV-50 compressor.

With these compelling findings, Bunge Oil could enhance its efficiency, reduce energy consumption and ultimately bolster its bottom line.

The Results

As a result of this study, Quincy Compressor effectively built a strong case for implementing various improvements at the plant.

Firstly, our team discovered that Bunge Oil’s plant had several large receiver tanks that were over 40 years old and no longer aligned with corporate safety guidelines. Quincy suggested replacing these tanks to ensure compliance with safety standards and maintain a secure working environment.

The audit also revealed that the plant was using desiccant dryers set at a dew point lower than necessary for their operations. Recognizing this inefficiency, we recommended transitioning to refrigerated dryers. By doing so, the plant stood to benefit from an additional 15% energy savings while still meeting the required dew point.

Additionally, Quincy presented a compelling argument for investing in a new nitrogen generator. This strategic decision ensured that all equipment within the plant would be on the same replacement life cycle, optimizing efficiency and reducing the risk of unexpected failures.

By actively identifying and proposing these improvements, Quincy provided Bunge Oil with a comprehensive solution to enhance their operations.

Quincy Compressor’s Impact on Bunge Oil

Quincy Compressor’s partnership with Bunge Oil has exemplified our unwavering commitment to delivering reliable, efficient and innovative solutions tailored to the unique needs of our valued customers. By conducting a comprehensive EQ LTE audit and proposing strategic improvements, we successfully revolutionized efficiency and performance within Bunge Oil’s operations.

We engineer our air compressor systems to withstand challenging applications and build them to withstand decades of heavy use. With durability and rugged efficiency at the core of our lineup, we provide a comprehensive range of air compressors, controls, accessories and air treatment options.

We invite you to experience the Quincy difference and discover how our solutions can transform your operations. Whether you require a reliable compressor system for your specific needs or seek to optimize efficiency and reduce costs, our team of experts is ready to assist you.

Take the first step towards transforming your operations. Request a consultation with our experts at Quincy Compressor to explore customized solutions that align with your unique needs and goals. Let us help you achieve unparalleled performance and reliability.

Download Case Study

View Quincy Compressor case studies

The post Bunge Oil – EQ LTE Audit appeared first on Quincy Compressor.

GoldenCorr Sheets is Southern California’s premier provider of corrugated sheets to the converting industry. GoldenCorr is in the heart of the Los Angeles County, City of Industry, California, and has been operating for over 20 years. In those 20 years, GoldenCorr has become one of the largest sheet feeder operations in North America.

GoldenCorr had three 200-horsepower(HP) competitor air compressors. Two of the compressors were from 2002, and the other was more recent, from 2019. GoldenCorr had spent lots of money on repairs over the last 20 years and did not want to keep throwing money on repairs on compressors that were on their last leg. It was time to replace two of the compressors and find solutions to some of their inefficiencies.

The Challenge

Prior to the Quincy EQ air rating study, GoldenCorr had several pain points with their air compressors. These challenges included:

• Low pressure alarms: GoldenCorr had air pressure drop issues at the end of their air lines. The machine at the end of this line would alarm if the pressure fell below 98 PSIG.
• Inefficient after-coolers: Because they are a paper plant, GoldenCorr had issues with tiny paper fibers clogging up the after-coolers. These fibers are a natural byproduct of production but caused high-temperature shutdowns that halted operations. With paper fibers going into the air-end of the air compressors, they were causing damage.
• GoldenCorr was also running two 200-horsepower non-VFD compressors. Even though the compressors ran in modulation, there was still a lot of room for improvement.

The Action Plan

To earn this job, Quincy Compressor needed to excel over five other air compressor competitors.

The main competitor was able to do an air study prior to Quincy Compressor’s study. Their recommended solution was a 200-HP VFD compressor and two 150-HP Load/Unload compressors.

Quincy Compressor wanted to see if there was another solution that solved the pain points and allowed the customer to save more operating costs. A local EQ-trained distributor arrived to conduct an air study. GoldenCorr mentioned that they had removed an air pump from their system process and planned to remove a second pump. This was all done after the initial air study by the competitor. In essence, these actions voided the air study.

The Quincy Compressor distributor mentioned to GoldenCorr that they may be able to go down in horsepower usage. The distributor explained that if they did another study after GoldenCorr took the second pump offline, they could see their true horsepower demand moving forward.

Quincy EQ Analysis

The distributor conducted an air study by installing EQ data loggers before and after GoldenCorr removed the second pump:

• They were able to collect critical information about system performance.
• The data collected from the EQ Logging Equipment analyzing the site information was uploaded to the EQ website.
• The EQ website’s patent-pending technology measured the existing system’s performance and modeled several potential system configurations to find the most effective solution.

This air study yielded an action plan for GoldenCorr to reduce horsepower. The data found that the GoldenCorr plant could run on a QSI-150 as the base-load air compressor. The plant could then use a QGV-150 as a trim compressor. This solution would take 100-HP offline, providing GoldenCorr with significant energy and cost savings.

The distributor tailored the solution to GoldenCorr’s needs by asking questions about their future needs and finding out that the customer would be lowering their air demand. The distributor spoke to GoldenCorr about air usage and discovered that the more air demand that can be taken offline, the smaller the horsepower of the air compressors needed to run the GoldenCorr facility. By asking these questions and understanding the customer’s needs, the distributor became the trusted consultant among the competitors.

Quincy EQ Results

Before the Quincy EQ air study with the second pump removed, GoldenCorr’s data revealed that:

• The plant’s kW usage was between 310 kW and 390 kW.
• The plant air pressure was not steady and jumped between 87 PSIG and 107 PSIG.
• When the air pressure dropped below 98 PSIG, the last machine alarmed.

After the air study, which was done after the second air pump was taken offline:

• The kW usage dropped to between 160 kW and 270 kW, a much more acceptable level for the customer.
• GoldenCorr’s kW savings were between 150 kW and 210 kW.
• The plant pressure remained steady between 98 PSIG and 112 PSIG.
• The steady pressure removed the fear that the alarm at the end of the air line would go off, reducing the chances of an emergency system shutdown.

“I tailored the solution to the customer’s needs by asking questions about the customer’s future needs and finding out that the customer would be lowering his air demand. I spoke to the customer about air usage; the more air demand he is taking offline, the smaller the horsepower of the compressors needed to run his facility. By doing this, I became the trusted consultant.” – Francisco Casique, Quincy Sales Engineer

The Quincy Solution

To address all of GoldenCorr’s pain points, the Quincy Compressor distributor had to engineer a unique system. This air compressor system needed to resolve the clogged after-cooler issue and eliminate high-temperature system shutdowns. A solution to these issues demanded a whole-system approach. The distributor’s solution included two primary stages:

1. Eliminating the paper fiber clogging issue: To remove the issue of paper fibers clogging the after-coolers and going into the air-end, the distributor had a contractor install air vents to feed the outside air to the air compressor’s inlet. These air vents work by keeping the after-cooler free of paper fibers, dust and other debris to keep temperatures at the proper level efficiently. The contractor also installed package pre-filters on each air compressor for additional efficacy at filtering obstructions.
2. Lowering the room’s temperature: Also, to remove the excess heat from the room, the contractor installed a duct that exhausts through the roof. This exhaust, along with the air vents, removes the possibility of hot air being recycled. Lowering the temperature within the compressor room reduced the chances of the compressor going down due to overheating.

Together, these solutions prevent slow-downs and inefficiencies in the after-coolers and air compressors.

The distributor also recommended that GoldenCorr order replacement equipment, like new air compressors. Due to the lower air demand from removing the pumps from the system processes, using more efficient equipment will further help GoldenCorr reduce operating costs.

Download Case Study

View Quincy Compressor case studies

The post GoldenCorr Sheets – EQ Analysis Study appeared first on Quincy Compressor.