Compressed Air Consumption Reduction Case Study

This case study documents the application goal of reducing compressed air consumption and noise levels associated with the inappropriate use of modular hoses designed for liquids. Initially, a steel tubing fabricator utilized a modular hose that provided adequate cooling flow but was identified as inefficient, resulting in a total compressed air consumption rate of 197.5 SCFM at 90 PSIG and a sound level of 96 dBA during 72 hours of operation each week. After implementing four Model 1103-9256 Mini Super Air Nozzles with 6” Stay Set Hoses, the air flow continued to ensure reliable heat protection for the sensors while significantly decreasing compressed air consumption to 44.2 SCFM at the same pressure and noise levels to 72 dBA. The installation process was quick, and the total investment was $1,520.00, with a return on investment realized on the ninth day of operation, leading to plans for upgrading additional roller lines in the plant.