In cardboard production, manufacturing often runs in multi-shift operations, and compressed air is involved at many points in 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 status of the system at any time.

This was implemented with three parallel-connected screw compressors of the STRONG 37 type. A higher-level system management makes the operating status of the machines visible, and in the event of a standstill, the information can be passed directly to the service center.

Initial Situation

The packaging and cardboard industry relies on a continuous compressed air supply. When systems run in cycles and several process steps access compressed air, an unplanned stop has an immediate impact on production.

A single, large-scale compressor would be a risk: if it fails, the supply stops. Therefore, a solution was sought that distributes the load across several machines while making the system’s status transparent – so that in the event of an emergency, there is no need to search for which machine is affected.

Technical solution

Three compressors from the STRONG series, each with a nominal power of 37 kW, were installed. These are oil-injected screw compressors with speed-controlled IE4 permanent magnet motors. The speed control adjusts the amount of air generated to the actual demand, which is helpful in production with fluctuating air requirements.

The compressor control provides operating information for the respective machine. Three compressors of the same size 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.

System concept: Parallel operation with status monitoring

The three compressors work in parallel on the common compressed air network. A higher-level system management bundles the information from the machines so that the machine status is visible centrally. The operation therefore not only sees that compressed air is present, 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 center. This allows information about a machine standstill to be passed directly to the service center. The specific technical design depends on the system management used.

Result and operational benefits

The project goal was an available and transparent compressed air supply. The system concept results in the following points:

• The supply is based on three machines instead of a single compressor.
• The machine status of the compressors can be viewed centrally.
• If a machine stops, the information can go directly to the service center.
• Dependence on a single machine is reduced – the extent of the reserve depends on the design.

Three points for an available compressed air supply

1. Multiple machines distribute the risk. Three smaller compressors handle the failure of a unit better than a single large machine. The size of the remaining reserve depends on the design and the actual air requirement.
2. Visibility shortens response time. A centrally viewable machine status and a direct report to service shorten the time from the fault to the response – often just as important as the pure number of machines.
3. The design determines the benefit. How many machines of what size make sense should be determined via a specific demand calculation, instead of relying on a large unit as a rule of thumb.

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. How large this reserve is depends on the design of the system and the actual air requirement.

What does system monitoring mean for compressors?

System 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 present at all. The exact scope of information depends on the control and system management.

Is the service center informed if a machine stops?

In the present project, in the event of a standstill, the information can be passed directly to the service center. This shortens the path from the fault to the response. The exact technical design should be coordinated on a project-specific basis.

Is the concept also suitable for other cycle-based productions?

Yes. Wherever a continuous compressed air supply is important and unplanned stops are expensive, the combination of distributed load and visible system status makes sense. The specific design depends on the respective requirement.

Check compressed air supply for cardboard production

Are you planning a similar solution for packaging or cardboard production? Let us know the operating pressure, air requirement, operating times, and the most important requirements of your application. This will clarify how many machines make sense and how the system status can be made visible. SCC and the regional partner network support you with technical advice – the basic idea of networked compressors can be included.