Inadequate compressed air distribution network caused quality issues at plastic moulding operation.
Through a recently completed energy audit at a plastic moulding plant we have established that a state-of-the-art variable speed compressor fed a dead-end distribution network, which was too narrow for the load.
Compressed air distribution network can block air from reaching the machines. Big trouble.
From time to time demand for air by machines connected upstream caused shortage of air at downstream machines. As a result, the downstream machines had unexplained periods of high scrap rate, which put a new production program for an automotive client at risk. In attempt to cure the problem operators increased pressure to 150 psi while machines only required 90 psi, but this did not help.
And, yes, network was leaking 35% of air too. In this case cost of leaks was not even important.