Air Recovery & Air System Optimization
One of the energy efficiency measures we implemented in this case works to recover a portion of the high-pressure air used in the blow-molding cavities. That recovered air is then piped into the main low-pressure system, which reduces the demand on the main system and low-pressure compressors.
Air recovery systems like this can save anywhere from 10% to 40% of energy costs. Typically, savings are around 25%. The system we proposed at this particular facility was the Technoplan ARS system.
During the older process, every bottle form was filled with a certain volume of compressed air to take its desired shape. Previously, that compressed air was then just released and went to waste. Now, that air is captured and redistributed back into the beginning of the process, ready for the next preform.
Lamp Optimization & Ceramic Reflectors
These blow-molding units have infrared heat lamps. These lamps have a wide angle of coverage. They are turned on and off based on the recipe and target temperatures of the portions of the preforms. By installing ceramic reflectors, we can refine the angle of the lamps’ coverage.
This allows for more direct heating of the preforms and wastes less heat overall. The installation of the ceramic reflectors requires installing the product and optimizing the angle of the lamp. There are a series of required tests that ensure the preforms are being properly heated.