System Integration & Control Systems Design


Compressed air savings in egg carton production

February 2021 System Integration & Control Systems Design

US expert for industrial compressed air systems, iZ Systems, offers energy audits and other services to reduce energy consumption. Using open PC and EtherCAT-based automation technology, the company has developed a compact standard controller that enables remote monitoring and optimisation of compressed air systems. This enabled food packaging manufacturer, Pactiv, to achieve enormous energy savings following an equipment upgrade and to secure these savings in the long term.

While many companies claim their products or services pay for themselves, iZ Systems can actually prove it. The Georgia-based company provides energy auditing services and control systems that quickly deliver a complete ROI from the resulting energy reductions.

For seven years now, iZ Systems has been providing these services to Pactiv, which focuses on moulded fibre egg cartons. The partnership began with a project to replace the compressed air systems supplying low-pressure blowers, according to David Powell, maintenance manager for Pactiv. “With every blower we tested, the pressures would change too much even if a single nozzle was adjusted,” he says. “The iZ Systems team promised a blower system that would not change in pressure, even if you shut off all but one nozzle, and their system has worked flawlessly.”

Open technologies deliver valuable insights

To ensure that customers’ systems achieve peak performance, iZ Systems must be able to monitor data remotely and make adjustments whenever necessary. In addition to its audits, the company accomplishes these goals through its turnkey iZ Compressed Air Automation and Data Acquisition System, which combines the automation controller, I/O and HMI in a single control cabinet and utilises custom software. Leveraging the open control technology from Beckhoff, the system has been providing connectivity to clients’ diverse networks for years now.

Visualising the numerous compressors and equipment spread throughout entire plants can easily clutter an HMI, so iZ Systems has standardised on the CP2924 multi-touch control panel. The 24-inch widescreen panel is mounted into a control cabinet cut-out to enable easy identification of field components, according to Allen King Jr, inside application project manager.

The go-to machine controller is a DIN rail-mounted CX5140 embedded PC, which reduces space requirements in the control cabinet, while providing advanced capabilities not available in traditional PLCs.

Stratospheric energy savings, guaranteed

By implementing these open, PC-based solutions, the engineering team at iZ Systems was able to keep its promise to Pactiv. As a result of the blower equipment upgrades, Pactiv reduced its energy consumption for compressed air by 45%. “By using blower air, we replaced nearly 300 kW of compressed air with 37 kW. This amounts to a cost saving of nearly $250 000 each year,” says Powell. “The improvements to our air compressor design have stabilised our pressure, and the remote monitoring has given us peace of mind.”

More importantly, the systems with Beckhoff components achieve the utmost reliability. Secure communication with customer machinery via OPC UA allows iZ Systems to monitor any changes in performance and to initiate maintenance measures early on if required. Powell says this, along with excellent support, has been crucial for Pactiv: “The system alerts me when there are any abnormalities with the compressors, but iZ gets the warnings as well and their engineers are usually working to address the issue before I call them.”

Win-win solution for customer and end users

In addition to boosting reliability, iZ Systems has reduced control cabinet footprint by two thirds on average by implementing Beckhoff controls. “Our old control cabinets were much larger because the previous PLC generated an excessive amount of heat, increasing our cooling requirements and energy consumption,” says King. “With the Beckhoff hardware, heat generation is not a problem and we increased our own energy efficiency like we do for our customers.”

In addition, the flexibility and scalability of Beckhoff components allows iZ Systems to build and stock standard control cabinets for future use, rather than designing a custom cabinet for each client.

By creating open systems that support multi-vendor architectures, iZ Systems has the unique opportunity to apply energy-saving solutions from one industry to another. “We try to make the initial acquisition cost attractive to the client while guaranteeing major energy reductions, and the Beckhoff platform has made a huge difference in our ability to meet these goals,” concludes King.


Credit(s)



Share this article:
Share via emailShare via LinkedInPrint this page

Further reading:

Integrating fire alarm systems into building management systems
Beckhoff Automation Fieldbus & Industrial Networking
Fire alarm systems work independently of the building automation system. Schrack Seconet has developed a flexible gateway using ultra-compact industrial PCs and TwinCAT from Beckhoff, which can be used to flexibly convert a customer-specific communication protocol to a wide range of transmission standards.

Read more...
PC-based control regulates innovative dehumidifiers
Beckhoff Automation IT in Manufacturing
The Swedish company Airwatergreen AB is breaking new ground in the dehumidification of air in industrial buildings and warehouses. PC-based control from Beckhoff regulates the innovative process.

Read more...
PC-based control regulates innovative dehumidifiers
Beckhoff Automation Fieldbus & Industrial Networking
Swedish company, Airwatergreen is breaking new ground in the dehumidification of air in industrial buildings and warehouses. The patented CVP technology reduces energy requirements and ensures an indoor climate that prevents corrosion and mould growth. PC-based control from Beckhoff regulates this innovative process.

Read more...
PC-based control in window and door production
Beckhoff Automation Motion Control & Drives
Belgian machine builders CNC Solutions and Calvet are automating previously manual processes in aluminium window and door production. High-performance drive technology, motion control and electric cylinders from Beckhoff proved crucial in equipping the machine with the necessary finesse when pressing the window frames.

Read more...
Control system upgrade: Smelting
SAM Systems Automation & Management System Integration & Control Systems Design
Systems Automation & Management recently completed a major control system upgrade in the smelting industry. The project was delivered on budget and achieved a positive ROI for the client.

Read more...
Gottwald drives upgrade: Ports and harbours
Abacus Automation System Integration & Control Systems Design
In the ports and harbours sector, Abacus Automation completed a significant modernisation of a Gottwald crane, improving both operational reliability and serviceability.

Read more...
Mining industry upgrade: From ageing systems to maximum capacity
System Integration & Control Systems Design
Iritron recently undertook a major upgrade in the mining sector, focusing on washing and screening plants, jigs, thickeners, tailings, water systems, conveyors and reclaimers.

Read more...
Agogo Integrated West Hub Project: FPSO/subsea offshore Angola
Moore Process Controls System Integration & Control Systems Design
The Agogo Integrated West Hub project represents a historic milestone in the FPSO and subsea industry, achieving first oil offshore of Angola. This project is the first FPSO deployment since ANPG’s establishment in 2019, and the first major project for Azule Energy since 2022.

Read more...
Integrated Robotics and Control Systems Deliver 45% Production Boost at Aquazania Waters Project and Industry
Process Dynamics System Integration & Control Systems Design
Project and Industry    Process Dynamics designed and commissioned a state-of-the-art Reverse Osmosis (RO) water purification and automated bottle filling plant for Aquazania Waters in Linbro Park, Johannesburg. ...

Read more...
Pluggable system solution helps tackle skills shortages and addresses DC power supply needs
Beckhoff Automation Enclosures, Cabling & Connectors
As a replacement for the conventional control cabinet, the MX-System from Beckhoff is a uniform modular automation system that can be used to completely replace traditional control cabinets with function modules in many applications.

Read more...









While every effort has been made to ensure the accuracy of the information contained herein, the publisher and its agents cannot be held responsible for any errors contained, or any loss incurred as a result. Articles published do not necessarily reflect the views of the publishers. The editor reserves the right to alter or cut copy. Articles submitted are deemed to have been cleared for publication. Advertisements and company contact details are published as provided by the advertiser. Technews Publishing (Pty) Ltd cannot be held responsible for the accuracy or veracity of supplied material.




© Technews Publishing (Pty) Ltd | All Rights Reserved