The AirFlowSaver significantly reduces CO² emissions

CO² emissions have become the leading topic in the climate debate.

 It is charged in the form of the energy tax on every kilowatt hour purchased; the CO² tax, which will be included in the price kilowatt hour, is charged in the form of compliance with legal requirements such as the new European Energy Efficiency Directive and is transparent if you need to disclose your company’s CO² emissions to customers and investors.

Either way, like our planet, your factory is already affected by carbon. In order to be accepted as a sustainable company in the future, it will not help just to plant trees, but to reduce the sources of its own emissions to a large extent.

Projects in factories around the world show that the easiest and most cost-effective way to reduce CO² emissions is to optimize your compressed air system. Compressed air most likely runs a large part of your production processes and is usually the most expensive source of energy. The TCO of a compressed air system consist of 5% Investment25% service cost and 70% energy cost. This is because compressed air generation is a very inefficient process. Companies around the world spent approx. 100 bn $ energy cost / per anno by using 1,000 bn kw/h of energy for the usage of compressed air. This process generate approx. 700 mio. tons of CO²!

Hard to believe, but true: The average compressed air system emits 30-50% more CO² than necessary. This also means a 30-50% higher electricity bill than necessary for a process that often consumes a large part of the electricity of a plant.

70% of all compressed air applications take place at so-called blow-off stations. This is where drying, cleaning or sorting takes place. This is where our AirFlowSaver is used, which saves up to 95% of the compressed air at blow-off stations. The innovative technology only blows in real-time when needed and also achieves an increased impulse blow effect by 10 to 25% for a better performance.

For illustration: A beverage bottler blows tetrapacks dry at the blow-off station before they are printed. Every second, 5 tetrapacks pass the blow-off station and are blown continuously. After installing the AirFlowSaver (AFS) at the blow-off station (point of usage), the customer saves 80% compressed air. The AFS detects when a tetrapack passes the station and opens for 40 ms each time. In total, 800 ms are saved per second. In addition the customer reduces his compressed air system from 6 to 2 bar. The amortisation for the investment (without energy policy subsidies) is less than one year.

The fact is that most, if not all, users of compressed air burn CO² for no other reason than lack of systems or information. 

 Below are some averages for financial waste and unnecessary CO² emissions for a well maintained plant with only 30% leaks and inefficiencies (kWh prices and CO² emissions) that you can associate with your own plant:

 250kW compressor power – 230 tons of CO² and 65,000 EUR annually 

1000kW compressor power – 920 tons CO² and 260.000 EUR per year 

5000kW compressor power – 4.600 tons CO² and 1.300.000 EUR per year 

The CO² savings achieved with the AirFlowSaver are one of the highest you can achieve on the market. In addition, reducing the CO² intensity of your compressed air system will not only reduce your company’s environmental impact,but will also contribute to your bottom line within the first year of implementation

We argue that compressed air savings are by far the cheapest, fastest and easiest way to reduce carbon emissions. In average every AFS system reduces between 10 to 15 tons of CO² per anno – the effect of 1,000 trees. The key is to do it the right way and with the right tools.

 If significant CO² reductions and return on investment within a year are not enough to act, then perhaps the following reasons are more compelling:

1. an optimally managed compressed air system reduces the risk of downtime and quality problems caused by unstable compressed air supply;

2. efficient compressed air systems provide high levels of satisfaction for you, your employees and customers, and tangible results that flow into your annual reports and ISO requirements for continuous improvement; and

3. you can significantly reduce your total investment and operating costs over the life of the compressed air system. 

 To learn more about how KTW Technology can help your company reduce CO² emissions and become part of the solution, simply contact us!

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