Case Study: Enhanced Compressor Monitoring through AIRMATICS
Background
A leading beverage bottling facility in the United Kingdom faced limitations with their existing compressor control and monitoring system. Their original OEM SmartAir Master was proving inadequate for managing newer, more complex compressors integrated into their production line. The facility required higher levels of monitoring precision and system visibility than what the legacy solution could offer.
Challenges
- Incompatibility with Modern Compressors: The OEM SmartAir Master failed to efficiently manage newer-generation compressors introduced as part of a facility upgrade.
- Insufficient Monitoring Depth: The system lacked the capability to deliver high-resolution, real-time monitoring across compressor assets.
- Lack of Asset-Level Data: Operators couldn’t view or assess the health or performance of individual compressor units.
- Missing Flow & Power Measurements: Key performance indicators such as flow rate and energy consumption were not being captured, limiting the team’s ability to troubleshoot or optimise performance.
Solution
To address these monitoring shortfalls, the facility deployed the AIRMATICS AERO system. The solution included:
- Installation of AIRMATICS AERO: Equipped with SmartTags, flow sensors, dewpoint sensors, and temperature sensors for comprehensive data acquisition.
- Data Accessibility via AirCloud & LAN: Operations staff gained immediate access to real-time and historical performance data remotely and locally, enabling proactive decision-making.
Impact
By implementing AIRMATICS, the bottling plant transformed its compressor management approach:
- Achieved full visibility of flow and power metrics across all assets.
- Enabled asset-level tracking, simplifying maintenance planning and issue diagnosis.
- Established a modern data-centric infrastructure for monitoring and reporting, tailored for evolving operational needs.
- Positioned the facility for future-ready upgrades with scalable monitoring tools.
Representative Quote
“The AIRMATICS control system was originally included as part of a compressor replacement project. However, after trying to re-use the outdated SmartAir Master, it became clear that this solution should have been kept in the original scope all along.”
Summary
AIRMATICS delivered a transformative upgrade through the deployment of Aero hardware and SmartTags, giving the facility real-time visibility into compressor performance via AirCloud. This enhanced system enabled precise asset-level monitoring, including flow, power, temperature, and dewpoint data, capabilities that were previously lacking.
As an added bonus, the improved insight and control translated into measurable benefits: over 35,000 kWh in annual energy savings, £8,760 in cost reductions, and 7,904 kg of CO₂ emissions avoided. This case demonstrates how modern monitoring solutions not only resolve operational blind spots but also contribute to meaningful efficiency gains.