In cardboard production, manufacturing often runs in multi-shift operation, and compressed air is involved in many stages of the process. If it fails unexpectedly, more than just one machine quickly comes to a standstill. For a cardboard processing company in Lombardy, it was therefore crucial not to be dependent on a single compressor – and to be able to view the plant’s status at any time.
This was achieved with three screw compressors of type STRONG 37 connected in parallel. A higher-level plant management system makes the operating status of the machines visible, and in the event of a standstill, the information can be passed directly to the service centre.
Key points at a glance
- Client: a cardboard processing company in Lombardy (Italy).
- Solution: three SCC STRONG 37 screw compressors (37 kW) connected in parallel.
- Challenge: Ensure availability and maintain transparent plant status.
- Benefit: centrally viewable machine status and the ability to report a standstill directly to the service centre.
Initial Situation
The packaging and cardboard industry relies on a continuous compressed air supply. When plants run in sync and multiple process steps access compressed air, an unplanned stop immediately affects production.
A single, large-sized compressor would be a risk: if it fails, the supply stops. Therefore, a solution was sought that distributes the load across multiple machines and simultaneously makes the plant’s condition transparent – so that in an emergency, there is no need to search for which machine is affected.
Technical solution
Three compressors from the STRONG series were installed, each with a nominal output of 37 kW. These are oil-injected screw compressors with a speed-controlled IE4 permanent magnet motor. The speed control adjusts the generated air volume to the actual demand, which is helpful in production with fluctuating air requirements.
The compressor control provides operating information for the respective machine. Three equally sized compressors instead of a single large unit also have a practical advantage: the load can be distributed, and in the event of maintenance or a machine standstill, part of the supply is maintained – the exact extent depends on the design.
Plant Concept: Parallel Operation with Status Monitoring
The three compressors operate in parallel on the common compressed air network. A higher-level plant management system bundles the information from the machines, making the machine status centrally visible. The operation therefore not only sees that compressed air is available, but also the condition of the individual compressors.
A central component is the notification: if a compressor stops, the information can be passed directly to the service centre. This means that information about a machine standstill can be passed directly to the service centre. The specific technical design depends on the plant management system used.
Result and operational benefits
The project goal was an available and transparent compressed air supply. The plant concept results in the following points:
- The supply relies on three machines instead of a single compressor.
- The machine status of the compressors is centrally viewable.
- In the event of a machine standstill, the information can go directly to the service centre.
- Dependence on a single machine is reduced – the extent of the reserve depends on the design.
Three points for an available compressed air supply
- Multiple machines distribute the risk. Three smaller compressors absorb the failure of one unit better than a single large machine. The size of the remaining reserve results from the design and the actual air demand.
- Visibility shortens reaction time. A centrally viewable machine status and direct notification to service shorten the time from fault to reaction – often just as important as the sheer number of machines.
- The design determines the benefit. How many machines of what size are sensible should be determined via a concrete demand calculation, instead of generally opting for one large unit.
Frequently Asked Questions
Why three compressors instead of one large one?
Multiple machines distribute the load and the risk of failure. If one machine stops, part of the supply is maintained. The size of this reserve depends on the plant design and the actual air demand.
What does plant monitoring mean for compressors?
Plant monitoring means that the operating status of the machines is visible. This makes it possible to see the condition of the compressors – not just whether compressed air is available at all. The exact scope of information depends on the control system and plant management.
Is the service centre informed if a machine stops?
In the present project, in the event of a standstill, the information can be passed directly to the service centre. This shortens the path from fault to reaction. The exact technical design should be agreed upon on a project-specific basis.
Is the concept also suitable for other cycle productions?
Yes. Wherever a continuous compressed air supply is important and unplanned stops are costly, the combination of distributed load and visible plant status makes sense. The specific design depends on the respective requirements.
Check compressed air supply for cardboard production
Are you planning a similar solution for packaging or cardboard production? Tell us your operating pressure, air demand, operating hours, and the most important requirements of your application. This will clarify how many machines are sensible and how the plant status can be made visible. SCC and the regional partner network will support you with technical advice – the basic idea of networked compressors can be included.