Powerful solution for hot processes: the SCC STRONG compressor in metal galvanising

Sustainable solution thanks to efficient SCC STRONG compressor with heat recovery

A company from the metal galvanising sector, based in Italy, was looking for a sustainable solution to increase the efficiency of its production processes. As a provider of high-quality galvanising services, the company supplies a variety of industries – from construction and mechanical engineering to the automotive sector. Continuously rising energy costs and the demand for resource-saving processes made a technical modernisation indispensable.

Challenges

The focus was on heating the galvanic baths, which play a central role in the galvanising process. Until now, these baths had been heated by conventional means, resulting in high energy consumption and correspondingly high operating costs.

Additionally, the existing compressed air supply suffered from inefficient technology, fluctuating pressure levels, and increased maintenance requirements. The management was therefore searching for a solution that could address both challenges in one step.

Solution and start of partnership with SCC

The company opted for an innovative solution from SCC air compressors: In June 2024, a STRONG series compressor with integrated heat recovery was installed and commissioned. The directly driven inverter compressor with 37 kW output not only supplies the plant reliably with compressed air but also heats the galvanic baths to the required process temperature of 55 °C via suitable immersion coils.

Thanks to the integrated heat recovery, the waste heat generated during compression is intelligently utilised. This not only optimises the energy consumption for compressed air generation but also reduces energy usage in temperature regulation. The installed controllers operate with lower delta-T values, thereby requiring less electrical energy.

Measurable dual benefits: reduced energy consumption and process optimisation

Within 13 months, the positive effects on the company’s processes became clear, resulting in a win-win situation for efficiency, sustainability, and investment:

• Compressed air and heat supply in one system
• Energy savings through intelligent heat recovery
• Stable pressure thanks to inverter control
• Water heating up to 70 °C possible
• Direct drive and IE4 permanent magnet motor (efficiency class IE4)
• Variable output capacity
• Low maintenance costs
• 5-year warranty on the system

Particularly pleasing for the customer: the investment costs for the system were fully amortised after only 13 months.

Conclusion: efficient compressors as a key to process optimisation and cost savings

This case study clearly demonstrates how modern compressor technology can help achieve several corporate goals at once: reducing costs, using energy efficiently, and stabilising processes. SCC air compressors will continue to be a reliable partner to the company, offering customised solutions for energy-efficient, high-performance compressed air supply with added value.

Learn more about how you can optimise your production processes more efficiently and sustainably. Contact us – we’ll show you the compressed air potential for your application.