Client: Leading European building materials manufacturer
Location: France
Sector: Building Materials, Manufacturing, Mechanical Engineering, Packaging
In a high-demand manufacturing environment, compressed air is often the silent workhorse powering critical processes. For this major European manufacturer, managing a sprawling compressed air system across multiple locations posed significant operational and environmental challenges.
The Challenge
The manufacturer faced multiple systemic issues across its compressed air infrastructure:
- Decentralised Compressor Rooms
With 11 compressors spread across four different rooms, coordinating their operation efficiently was a growing concern. - High Energy and Maintenance Costs
There was a strong push to reduce not only operational expenses but also the environmental footprint of the compressed air system. - Insufficient Monitoring and Visibility
Key components – 13 dryers, 21 flow meters, 5 dewpoint sensors, and additional pressure sensors – were not fully integrated, leaving gaps in system oversight and performance data.
The AIRMATICS Solution
To address these issues, AIRMATICS delivered a fully integrated, intelligent control and monitoring upgrade:
- Installation of the AIRMATICS AERO System
A robust control system was deployed with Balance of Pressure and Zone Control capabilities, improving management across all compressor locations. - Advanced Monitoring Across All Assets
Strategic tagging allowed complete visibility of all critical equipment, integrating legacy and new assets into a centralised platform. - Multi-Level Data Access
The system was enabled for monitoring at the local, LAN, cloud, and MODBUS levels – offering flexible access to performance insights. - Ongoing Support Through ASSURE Contract
Extended warranty and support were included to ensure system longevity and peace of mind for the site’s operations team.
The Results
The upgrade delivered immediate and measurable improvements:
- Energy Savings: 1,438,567 kWh per year
- Cost Savings: €143,900 per year
- CO₂ Emissions Reduction: 889,034 kg per year
Customer Feedback
“The legacy Metacentre XC system, in operation since 2010, has now been successfully transitioned to the complete AIRMATICS platform. With features like pressure balancing, zone control, and comprehensive equipment monitoring, we now benefit from optimised system performance and full operational visibility.”