CASE STUDIES
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 Practical & professional compressed air service providers

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OceanaGold Macraes Flat, East Otago

Six-figure profits potentially rescued from the scrap heap at Macraes mine

Issue

Macraes is New Zealand’s largest gold producing operation. It’s been going for close to 30 years and operates open pit and underground operations in Macraes Flat, North Otago.’


It had two issues identified within its operations:

  1. A malfunctioning breathable air filter that provided breathable air to a safe room in the underground mine. Moisture was saturating the air filter elements causing rapid deterioration. These were needed to be replaced monthly at a staggering cost of $26,000 per month!
  2. Poor mechanical pneumatics within its raw material processing plant could be potentially responsible for six-figure losses in gold retrieval for OceanaGold. Further analysis proved this was so. New compressed air pneumatics to operate mechanical valves and pulleys were needed.



Action

PSL Total Air Invercargill analysed the problems in detail and provided a one-stop solution to both the gold retrieval and air supply issues they were experiencing. PSL Total Air installed a 

  • Kaeser TF340 refrigeration dryer plus filter unit for the underground safe room. This would remove moisture present, effectively slowing the deterioration of costly air filter elements.
  • New Festo pneumatics in processing plants to improve the functioning of mechanical parts. Leading to less lost gold particles to waste.



Result

Firstly and most significantly, improved gold recovery rates has the potential of earning OceanaGold close to a million dollars per annum. Repairing air leaks in the processing plant has been improving reliability and saving energy.


For the mine’s safe room the inclusion of the refrigeration dryer unit has dramatically cut costs for operations. It has reduced the need to replace expensive air filter elements every month to every six months.

Improving operational performance in its pneumatic system has the potential to save OceanaGold close to a million dollars in recovered gold particulates.

E’stel Water Bottling Plant, Nelson

Compressor solution meets the demands of a busy blow moulding machine

Issue

Due to steadily growing demand for their product, this premium alkaline water bottler based in Nelson, invested in a larger capacity PET blow moulding machine to make more bottles, faster.


This machine relies on a steady supply of compressed air. Because it can blow a staggering 11.000 bottles per hour, E’stel Water needed a new compressed air system that could keep up.


PSL Total Air was called upon to present a solution. One that could meet both the low and high pressure compressed air demand of the PET blow moulding machine.




Action

PSL Total Air Nelson set about installing a complete plug and play turnkey package which included a:

  • Kaeser CSD 105 rotary screw compressor 
  • Kaeser DN 22 series booster system

Booster packages are specifically designed for optimal pressure and air delivery. 


The DN series of boosters from Kaeser deliver all-round reliability and efficient control and monitoring of the compressor operation. All DN series Kaeser boosters are equipped with super-efficient IE3 class drive motors and a  dimensioned axial fan for reliable temperature control and energy efficiency.

Result

A tailor-made, cost-effective, state of the art solution for the bottling plant.  E’stel Water director Wayne Herring, says they know how reliable Kaeser brand compressors are, they already had two standard pressure Kaeser Aircenter systems.  “With the Kaeser DN 22 booster, we had a compressed air supply system to meet our exact needs. PSL Total Air delivered an energy-efficient and reliable supply of on-demand compressed air. Their after-sales service has also been fantastic,” Wayne says.

With the Kaeser DN 22 booster, we had a compressed air supply system to meet our exact needs.

PSL Total Air delivered an energy-efficient and reliable supply of on-demand compressed air. Their after-sales service has also been fantastic

Buller District Council Wastewater Plant, Westport

A bold move to try new screw type air blower pays off for Westport Wastewater Plant

Issue

When the Buller District Council needed to replace one of three existing air blowers which kept its Westport wastewater ponds circulating, it stipulated a desire for ultra-efficiency and reliability.


They needed an air blower which required minimal maintenance for it to operate continuously. They needed operational savings to be made and they were having trouble finding adequate solutions.


PSL Total Air had a bold new product available and this project led to a first of its kind solution in Australasia.



Action

Realising the district council needed to shift from its older roots type blowers to a more future-proofed screw-type blower, PSL Total Air set about installing the Kaeser brand

  • DSB22OL SFC screw blower 
  • Sigma Control 2 controller 

This innovative reliable performer is purpose-built for low pressure municipal and industrial water systems and is built to be tough and trouble-free. 

It features the world-renowned SIGMA profile rotors which offer efficiency gains of up to 35 percent. This ensures maximum savings to commissioning, operating, and maintaining the wastewater plant.


The new rotor technology is ideal for municipal and industrial wastewater treatments where blowers are in constant operation.



Result

The after-install analysis showed the Buller District Council had made the right choice with the new screw-type blower.  PSL Total Air Nelson manager Charles Walta said of the two air blowers, one runs 12 hours a day and the other 24 hours a day.


“So we found that the 12 hour a day compressor is looking at saving about $18,000 per annum in power costs to the council, and the 24 hour a day blower, a bit more than that,” says Charles.


The success of the first-ever Kaeser DSB220L screw blower to be sold in Australasia has beneficial applications for numerous other municipalities too.


PSL Nelson have since installed two new Kaeser DBS 221L blowers, bringing the number of Kaeser blowers to three, two of these being on-duty and one on standby. The two new blowers have proven to be even more efficient than the first one, a great result for the council.



So we found that the 12 hour a day compressor is looking at saving about $18,000 per annum in power costs to the council, and the 24 hour a day blower, a bit more than that

Dairy Works Cheese Factory, Hornby

Inventive ‘container solution’ for dairy factory expansion

Issue

This cheese cut and package factory were undergoing an expansion to their plant footprint which meant they had to remove their existing compressors. They needed a new multi-compressor station with increased capacity and improved security of supply. 


It had to be located somewhere near but outside the factory. In order to save on capital costs, it also had to stand alone but not require a new building to house it.




Action

PSL Total Air Christchurch set about recommissioning a 40-foot container, which was already on the property, to house the new multiple compressors and mainline filtration. Within it they installed the following Kaeser brand compressors:

  • ASD60T
  • SK25T
  • SK24T and SAM 4 
  • And a supervisory control launch and monitor system

PSL Total Air also shifted an existing Kaeser ASK27T compressor down the road to a nearby Dairyworks ice-cream plant. Aimed at ensuring the security of compressed air supply in conjunction with a Kaeser ASK26 already installed.

Result

This innovative container solution to the plant's capacity issues proved perfect. Not to mention, cost-effective as it saved on building costs and utilised existing compressors elsewhere.


The results for Dairyworks were:

  • Increased compressed air capacity & delivery at two plants
  • Retention of available floor space for future growth opportunities within the plant
  • Capital costs saved by converting an existing 40 ft container into a multi compressor station
  • Improved production efficiencies & dependability



This innovative container solution to the plant's capacity issues proved perfect. Not to mention, cost-effective as it saved on building costs and utilised existing compressors elsewhere

The Press Printing Plant, Johns Road, Christchurch

Multi compressor ‘container solution’ saves on costs for a printing plant

Issue

Breakdowns and stoppages are costly for printing plants on tight production deadlines. So keeping a reliable supply of compressed air on demand is crucial. When The Press experienced a failed speed drive on one of their compressors, they engaged PSL Total Air to present a cost-effective space-saving solution that would last.

Action

This job had some urgency about it so the first thing PSL Total Air did was supply a stand by compressor so production could continue while they designed and installed a multi-compressor station.


This needed to be reliable and efficient with a supervisory controller to monitor and record outputs. This solution had the following Kaeser compressors installed:

  • ASK34
  • SM13
  • An existing A.C GA 15 
  • All controlled by a Kaeser SAM4 supervisory controller


Result

A cost-effective, reliable, and robust multi compressor station which provided reliability of compressed air supply to the printing process.

 

For The Press, this meant no stoppages of air supply and a contained multi compressor station that hadn’t involved new building costs or increased existing footprint.



This meant no stoppages of air supply and a contained multi compressor station that hadn’t involved new building costs or increased existing footprint.

SRS New Zealand, Sawmill & Timber Packaging, Rolleston

Leasing a new multi compressor station a saving for busy timber plant

Issue

This timber packaging plant required an upgrade to its existing compressor station. Existing compressors were old and worn, which was becoming problematic and affecting production.


The company though didn't have available capital to invest in a brand new compressor station. The dilemma being they also couldn’t afford not to. So, PSL Total Air came up with a leasing arrangement for their compressors as a win-win for both parties.





Action

PSL Total Air set about drawing up a lease agreement the timber company could accept and replaced all existing old compressors in the wet mill with Kaeser compressors:

  • BSD75T SFC
  • SFC
  • ASK34T
  • ASD47T
  • Kaeser SAM4 supervisory controller



A speed drive and two fixed-speed compressors were included in this multi compressor station.




Result

For SRS New Zealand this solution proved ideal. The leasing agreement meant no capital outlay and immediate improvement in compressed air reliability. For SRS New Zealand this meant no downtime due to mechanical breakdown.



Also, the increased efficiencies lead to lower power consumption costs. The mill relies mainly on one smaller super efficient compressor in the station to undertake the bulk of the compressor tasks, thus saving power on excessive running costs.



The leasing agreement meant no capital outlay and immediate improvement in compressed air reliability. For SRS New Zealand this meant no downtime due to mechanical breakdown.

Pine Industries MDF Factory, Richmond near Nelson

Powerful air knife solution sweeps the dust off for MDF board manufacturer

Issue

Nelson Pine Industries Limited is the largest producer of MDF fibreboards and LVL timbers in the Southern hemisphere. Their Richmond processing factory employs 200 plus people and numerous local suppliers as part of its massive operation.


So when they were having problems with excessive fibreboard dust particles covering manufactured boards ready for packaging, they tried a number of compressed air blower solutions. All to little avail.


PSL Total Air Nelson was called upon to find and present a once and for all solution to the dust settling problem.






Action

PSL Total Air presented a powerful, energy and compressed air efficient solution. Designed to deliver a forceful uniform sheet of compressed air to any surface needing to be cleaned, dried, or cooled quickly.


This compressed-air blade-type solution is the American manufactured 

  • Exair brand Super Air Knife.

The most efficient compressed air knife on the market, it delivers smaller amounts of compressed air more precisely.  Its other advantages include its quietness in comparison with other blow-off solutions and its compact, ruggedness, and easy installation.

Result

The dust settling problem on the MDF product has been eliminated with the Exair Air Knife. Nelson Pine Industries are very pleased with its precision and reliability. Given that compressed air and electricity are both costly commodities, the Exair Air Knife has proved a super-efficient solution for Nelson Pine Industries because it provides twice the output for half the input.

The dust settling problem on the MDF product has been eliminated with the Exair Air Knife. Nelson Pine Industries are very pleased with its precision and reliability.

Rakaia Island Dairy Farm, Southbridge

Issue

Rakaia Island is a large farming operation in Canterbury, comprising six dairy units and a dry stock unit.  Each one runs as one farm in two locations, Rakaia Island and Woodstock.


Rakaia Island has a 2275 hectare milking platform and 4700 hectares of support land. The farm has over 50 staff and 9,000 KiwiCross cows.

Periodic failures of its dairy shed compressors led to a lot of maintenance costs. The shed’s 7.5kw piston compressors were struggling and there was no compressed air dryer to protect end-user equipment.



Action

PSL Total Air presented a solution that included replacing the aging 7.5kw piston compressors with the Kaeser SM13T screw compressor with integrated dryers.



Result

The new compressor immediately improved compressed air reliability of supply and aided the life expectancy of critical equipment. The quality of the compressed air was also improved and all milking systems are up to par,  much to the delight of the Rakaia Island dairy farm owners.

The new compressor immediately improved compressed air reliability of supply and aided the life expectancy of critical equipment.

WineWorks, Marlborough

Nitrogen and compressed air solution helps a busy wine facility meet their targets.

Issue

WineWorks provides wine bottling and warehousing services for many of New Zealand’s top wineries. Their Marlborough facility was facing some major issues with the nitrogen and compressed air supply on their five bottling lines, so they reached out to PSL Total Air Nelson for help.


Data analysis showed that their older nitrogen generators, compressors, and other pneumatic equipment were using significantly more power than was efficient. As a recently accredited Toitū Carbon Reduce business, this was a key place to start.


On top of this, the equipment was at the maximum capacity, as well as becoming old and unreliable, and WineWorks were facing frequent faults and breakdowns. With their former service provider being based outside of their area, they were often having to use their own engineers or subcontractors to fix these faults.


They needed a nitrogen/compressed air solution which would allow them to operate to their full capacity and more efficiently.

Action

PSL Total Air Nelson installed three brand new SYSadvance NitroGEN N325 nitrogen generators and two new Kaeser ASD60 screw compressors to go along with the two existing compressors. This system created a pool from which compressed air would be supplied to the production lines and nitrogen generators, reducing the load on each compressor.


There was also a range of other equipment installed to replace the old equipment, including a Kaeser SAM supervisory control unit, a Kaeser TE174 refrigeration dryer, Kaeser filters, receivers, and more.


The Nelson team installed the new equipment on a mezzanine so as to not take up any extra floor space and they were able to complete the installation without any disruption to WineWorks’ production.


Result

The equipment supplied by PSL Total Air Nelson went above and beyond what Wineworks were hoping to achieve.


They saw a massive improvement in their energy consumption, with the electrical energy component of production services costs dropping by almost 50%, helping towards their Toitū goals, having recently stepped up to being Carbon zero accredited. While energy costs only make up a fraction of production costs, every little bit helps at a time when all expenses are skyrocketing.


They were also able to achieve increased reliability across both the nitrogen and compressed air supplies with 100% redundancy achieved, meaning no more downtime and lower maintenance costs.


Additionally, their quality of air supply was improved to reach food grade standards and the purity of nitrogen produced was also increased.

They were also able to achieve increased reliability across both the nitrogen and compressed air supplies with 100% redundancy achieved, meaning no more downtime and lower maintenance costs.

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