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Compressed Air System Retrofitting Project Improves Productivity at a Foundry

In 1996, Cast Masters performed a compressed air improvement project at its foundry in Bowling Green, Ohio, in which the compressed air system was retrofitted with a more appropriately sized compressor to serve the foundryís processes. The foundry replaced two aging 50-horsepower (hp) compressors and one 25-hp compressor with a new 75-hp rotary-screw compressor. The project allowed the foundry to reduce its energy and maintenance costs, and improved productivity because the new systemís reliability sharply reduced production downtime. The annual energy and maintenance savings from the project were $15,000 and the reduced production downtime increased annual revenue by $18,000. Because the total cost of the project was approximately $20,000, the simple payback was 1.3 years.
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