In food production, every minute of downtime counts. SCC air compressors has already successfully solved this problem in previous food applications in France (with the company Feuillette). Based on this experience, a concept was developed for the German customer in close cooperation with Kronwald Druckluft- und Kompressorentechnik GmbH – our premium partner from Bremen – that completely redefines redundancy, efficiency, and maintainability.
The Challenge: Dependence on Two Machines in Full Operation
A leading food company in Germany was facing a classic production bottleneck. Two older screw compressors – one with a fixed speed, one speed-controlled – were running continuously at full load to meet the compressed air demand of the modern production plant. The consequences were clearly noticeable: hardly any reserves in the event of breakdowns, considerable operating noise that strained staff and, above all, production downtime was unavoidable during scheduled maintenance. This is not a viable scenario in the food industry, as downtime means lost production and potentially critical supply chain disruptions.
The Solution: Two STORM 30 Screw Compressors in Intelligent Alternating Operation
The answer to these requirements was clear: a switch to two STORM 30 screw compressors from SCC air compressors. The concept is for the two machines to share the compressed air requirements, not compete with each other. In normal operation, only one STORM 30 runs with a capacity utilisation of around 60–80%; the second machine is in standby mode, fully available. The compressors change roles every twelve hours – this results in balanced wear and maximum service life for both machines.
The clever part: Maintenance work can now be carried out during production. While one compressor is being serviced, the other continues to run without interruption. This redundancy significantly increased the plant’s production reliability – a 50% improvement to now 100% availability is a measurable strength for the customer.
Incidentally, one of the most persistent problems also disappeared: the new system is noticeably quieter in operation. The 30 kW STORM with its sound level of 65 ±3 dB makes a significant difference – especially because only one machine is running under load. For the staff, this is a noticeable gain in working comfort.
When designing this compressor system, it was clear from the outset that air hygiene was non-negotiable. The German food company therefore relies on SCC-FOOD – the food-grade oil from SCC air compressors. This oil is specially formulated for applications where potential product contact may occur. It meets the high standards of the food industry and gives the company the assurance that the highest compressed air quality is guaranteed.
The involvement of Kronwald as the implementing partner – an experienced specialist in compressor technology – not only ensured technically optimal installation but also the smooth coordination of all components. The result is a system that works reliably and is easy to maintain from day one.
Efficient Food Production: Alternating Operation and Low Energy Consumption
The alternating operation concept brings additional benefits beyond pure redundancy. If only one STORM 30 runs under 60–80% continuous load – instead of two older machines under full stress – energy consumption demonstrably decreases. The STORM optimally utilises its efficient, direct-drive compressor, which permanently lowers operating costs. For the customer, this means long-term economic efficiency without compromising performance or reliability.
The large compressor stage of the STORM 30 with its slow operating speed also contributes to the longer service life of all components. The high separation efficiency of the integrated oil separator system – combined with SCC-FOOD oil – ensures that the residual oil content in the compressed air remains minimal. This achieves a double effect: optimal air quality and reduced environmental impact.
Frequently Asked Questions about Redundancy Solutions in the Food Industry
Why is redundancy in compressor systems crucial in the food industry?
Food companies operate under strict regulatory requirements and must ensure continuous production. A compressor failure not only means downtime but potentially spoiled goods, jeopardised delivery obligations, and costly disruption. Redundant systems with alternating operation eliminate this risk. With two independently operating units – one of which is always available in standby – a safety fallback level is created that is indispensable for professional operations.
How does speed-controlled operation support energy efficiency and wear protection?
In the STORM 30, speed control (VSD technology) ensures that the machine always precisely adapts its performance to the current compressed air demand. In alternating operation with a partner machine in standby, this means: the running compressor almost never requires its maximum power. At 60–80% utilisation, the motor works much more efficiently, generates less heat, reduces wear, and significantly lowers power consumption compared to a unit constantly running at full load.
What role does food-grade oil play in applications with potential product contact?
Food-grade oils like SCC-FOOD are specially developed to leave no harmful residues – should direct or indirect contact with food occur. They meet strict food law standards and often also requirements of certification programmes (e.g., Food Safety Compliance). Their use signals not only technical competence but also responsibility. For food companies, this is a fundamental mark of trust.
Summary: Food Production Without Compromises
The switch to two STORM 30 screw compressors has meant a qualitative leap for this German food company. Higher production reliability, lower operating costs, maintainable without production downtime, and absolutely quiet – these are the tangible results. The alternating operation concept is not just a technical solution, but a business model for modern, demanding production.
SCC air compressors and partner Kronwald Druckluft- und Kompressorentechnik have thus proven that a well-thought-out compressor system – supported by proven screw compressor technology and specialised industry knowledge – can significantly increase efficiency and reliability in the food industry.
Let our experts advise you and plan your system with SCC air compressors. We combine performance with safety – for production that counts.