The company, which produces sterile liquid pharmaceutical products, requires compressed air that meets the stringent ISO 8573-1:2010 Class 1:2:0 standard for air purity. Previously, the facility relied on heated dryers that were increasingly unreliable and undersized compressors that often had to run simultaneously, leaving no backup capacity. What’s more, the compressors were becoming expensive to operate and, after just 10 years in service, the manufacturer had been advised that replacement was necessary.
Seeking a more reliable and energy-efficient solution, the manufacturer turned to Atlas Copco.
Over a three-week period, Atlas Copco used its Airchitect measurement tool to monitor the plant’s compressed air usage. The resulting report revealed significant inefficiencies and identified potential annual savings of £31,000 in compressor energy costs and an additional £14,000 from dryer energy savings. Since installing Atlas Copco’s solution, the plant’s energy consumption has reduced by over 180 MWh, resulting in a decrease of around 22% in energy costs and CO2 emissions.
Based on the plant’s actual air flow requirements, the company installed an Atlas Copco ZT 145 VSD+ oil-free compressor paired with an innovative MDGA 450 air-cooled rotary drum desiccant dryer and associated filtration. The MDG dryer supplies ISO 8573-1 Class 2 compliant, −40°C pressure dew point air without the energy cost typically associated with conventional desiccant drying.
Since installation, the new system has reduced the plant’s energy consumption by 31%, largely due to the low power requirements of the MDG dryer. Encouraged by these results, the company has ordered a second ZT 145 VSD+ compressor to replace its remaining legacy unit and a second MDGA450 dryer as well. The two compressors and two dryers will operate in a duty-standby configuration, ensuring redundancy and uninterrupted production.
To further safeguard operations and eliminate any unexpected call out or repair charges, the manufacturer has also opted for a five-year extended warranty service plan agreement. This plan includes preventive maintenance by Atlas Copco’s expert service team using genuine parts, along with five years of worry-free performance at a fixed annual cost.
