Case Study: Food manufacturer installs Champion air compressors

Green’s, a leading Australian owned food manufacturing company has
installed three new compressors from Sullair Australia based on the equipment’s
proven reliability. Green’s has been producing and distributing food products
at their Sydney plant since 1978.

Having already enjoyed the use of Champion compressors for a very long
time, Green’s decided to purchase three new compressors to replace two 37kW
Champion compressors, which had served the company well over 20 years, as well
as a 75kW Champion compressor, which was used for over 15 years and had clocked
up over 100,000 operational hours.

Green’s replaced the three long-serving compressors with two standard Champion
compressors and one variable output controlled Champion compressor. Key reasons
for selecting Champion compressors included proven reliability, energy
efficiency, Australian design as well as the quality support service they had
previously experienced from Sullair.

John Hadzic, Process Improvement Engineer at Green’s explained that they
were impressed with the longevity of Champion compressors and their minimal
service requirements.

Early stage consultations included site visits and discussions with both
the equipment/pipework installer and roofing/ducting contractors. The layout of
the plant underwent eight iterations before consensus was achieved. Milestones
included simplification of the pipework layout, air flow to compressors and
exhaust, access to all equipment, WHS compliance, and ease of removing
equipment for future upgrade/replacement.

Sullair also recommended replacing the solenoid operated drain valves with
Spirax Sarco mechanical drain valves, due to the corrosion in the receiver,
which resolved problems with drainage blockage

Prior to pipework installation, Sullair placed the equipment on the
floor and allowed Green’s to approve the locations. This enabled adjustments to
be made to ensure adequate access for cleaning around the equipment and
maintenance, visibility of controls and better utilisation of existing cable trays
and penetrations.

The installation of exhaust ducting, which protected the compressors
against overheating, required removing large extraction fans, replacing roof
sheeting and manufacturing skewed transition pieces to link the compressor
exhaust to the ducting.

Following the commissioning of the plant, the contractor inspected the
system in operation and was pleased to report that the doors were closed on the
plant room, all forced ventilation had been removed and the compressors were consistently
running around 20 degrees below their overheat trip temperature.

Green’s has now joined the Sullair ‘Partner Care
Service Program’ to ensure peace of mind for their compressed air requirements.

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