A plant expansion in food production almost always brings with it a question that is easily underestimated: How should the additional compressed air be generated? For a company in Bavaria, the answer was clear even before the first compressor was requested. In the existing plant, the technology had been running reliably for years with water-injected compression – and exactly this experience was to be continued in the new area.
For the expansion, therefore, a classic oil-injected compressor was not required, but rather an oil-free compressor with familiar, proven technology. Together with the SCC partner Druckluft Maydt GmbH, the decision was made in favor of the AQUARIUS 56 from SCC air compressors – not least because short-term delivery was important for the construction schedule.
Key Points at a Glance
- Anonymous food company in Bavaria expands production and requires additional compressed air for the plant expansion.
- The system is being converted from oil-lubricated to water-injected, oil-free compression – as a continuation of a technology already proven within the company.
- The AQUARIUS series from SCC air compressors is used – a proven oil-free compressor with water-injected technology.
- The SCC partner Druckluft Maydt GmbH delivered and managed the project competently, including short-term availability for the construction schedule.
Initial Situation
In the course of the plant expansion, the compressed air supply for the new production area had to be rebuilt. Unlike the original oil-injected setup, the decision was made to consistently use oil-free technology – in line with the high air quality requirements of food production.
The customer’s own experience was also a decisive factor: water-injected compression had already proven itself in the company for years. Instead of introducing a new, unknown technology, this proven principle was to be consistently continued – with a partner who brings experience to the table.
The solution: oil-free compressor with water-injected technology
With the AQUARIUS 56 from SCC air compressors, an oil-free compressor was available that addresses exactly this point. The AQUARIUS series completely dispenses with oil and other lubricants in the compression process and delivers compressed air according to ISO 8573-1 Class 0 – the highest purity class for compressed air. According to SCC documentation, an external fresh water connection is not required, as the system works with water recirculation.
The screw compressor used operates with a nominal power of 55 kW and an IE4 permanent magnet motor, which saves up to 10% energy compared to speed-controlled asynchronous motors. The speed control continuously adjusts the amount of air generated to the actual demand, while the water simultaneously handles cooling – a principle that enables low compression temperatures and thus consistently high compressed air quality.
For the customer, this meant: they were not presented with a new, unknown technology, but rather a further development of the proven water-injected compression – just from SCC air compressors.
Implementation and cooperation with Druckluft Maydt GmbH
The project was realized with the SCC partner Druckluft Maydt GmbH. The company is particularly experienced in water-injected compressor technology and competently supported the customer in the selection, delivery, and support of the screw compressor.
A short lead time was important for the construction schedule of the plant expansion. Here, the SCC partner moved quickly into implementation. The brief coordination and availability via SCC in Wendlingen also supported the flexible delivery. In total, the compressor was provided within a few weeks.
Result and benefits for the customer
Specific key figures for this project are currently not published. However, the following advantages for the customer can be noted from the course of the project:
- reliable, oil-free compressed air supply for the new production area
- appropriate continuation of the proven water-injected technology in the plant expansion
- competent technical support by the SCC partner Druckluft Maydt GmbH
- short delivery time, which supported the schedule of the plant expansion
Why this solution fits the application
For companies in the food industry, oil-free compressed air is not an option in many processes, but a requirement. Those who – as in this case – have already gained good experience with water-injected technology will find in AQUARIUS a solution that technically continues this principle consistently instead of forcing a system change.
Particularly in the case of plant expansions, where schedules rarely leave room for maneuver, it also becomes clear how important a partner with short response and delivery times is.
What other companies in the food industry can take away
- Oil-free compressed air according to ISO 8573-1 Class 0 can be implemented practically and reliably with water-injected screw compression.
- A change from oil-lubricated to oil-free technology does not have to be a realignment, but can consistently continue proven operational experience.
- In the case of plant expansions, an early exchange with the compressed air partner is worthwhile in order to plan delivery times realistically.
Frequently Asked Questions
What does “oil-free according to ISO 8573-1 Class 0” mean?
Class 0 is the highest purity class for compressed air according to ISO 8573-1. ISO 8573-1 Class 0 stands for particularly high requirements regarding the oil content of the compressed air. In the AQUARIUS series, compression is water-injected and without oil in the compression process. This is particularly relevant for sensitive applications such as food production.
What distinguishes a water-injected compressor from an oil-lubricated compressor?
In water-injected compressors such as the AQUARIUS series, water from the ambient air handles lubrication and cooling in the compression process. As a result, the compressed air is generated completely without oil, whereas oil-lubricated compressors require downstream treatment to remove oil components from the compressed air.
Why is delivery time often a critical factor in plant expansions?
Plant expansions usually follow a fixed construction schedule, into which the compressed air technology is integrated in terms of timing. Delays in compressor delivery can affect construction progress, which is why short, reliable delivery times are particularly important here.
Can you switch from oil-lubricated to oil-free compressed air technology without changing the entire system?
Yes, that is possible – as shown in this project. Oil-free compressors such as the AQUARIUS series can be used specifically for new areas or expansions without the existing compressed air infrastructure having to be completely rebuilt.
Is AQUARIUS also suitable for other industries with high air quality requirements?
Yes. In addition to the food industry, the oil-free, water-injected AQUARIUS series is also used in other industries with sensitive processes, such as pharmaceutical or electronics manufacturing, where compressed air without oil residues is required.