Food & Beverage Industry Finds Cost Savings Out Of Thin Air
Discover how a chance conversation about refrigerators led to saving a client nearly £10,000.
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FLIR Si2-Pro Acoustic Imager
Here at Red Current, we work with many large clients directly. However, we also work with electrical contractors to deliver our specialised surveys and reports.
As such, we have many conversations about the capabilities of thermal imaging technology in different industrial scenarios. One electrical contractor was trying to solve a challenging problem regarding glycol leaks from refrigeration pipework. And the idea of acoustic imaging came up as a possible option. “Would that work?”, he wanted to know.
“No, not in this case”, we said, “However, acoustic imaging is often used for compressed air leakage detection.”, as we tried to give him a greater insight into this relatively new technology.
Our quick-thinking electrical contractor knew just the client he could help. With the cost of food, fuel, utilities and labour increasing, one of his clients used a lot of compressed air. And he knew they were looking for ways to save costs.
What they needed was a compressed air leakage detector
In order to calculate compressed air leakage cost, we have to establish just how much air is being lost. So there has to be an audit. Which means there needs to be some kind of equipment that can detect leaking air.
This is where the Teledyne FLIR Si2 Pro comes in. This is a state-of-the-art acoustic imaging camera designed to visualise and locate sound patterns. It works by converting ultrasonic sound waves into a clear, visual representation. This means that, with a compressed air leaks audit, the smallest leaks are detectable - even within noisy industrial environments.
But what about downtime?
As a ‘just in time’ leading logistics company, the client was concerned about whether their production and packaging operation would have to be disrupted. We were able to reassure them that it was a completely non-invasive inspection, and their business could continue uninterrupted.
The Acoustic Imaging Trial
Would it really work? As a relatively new technology, there was a need to demonstrate the capability of the acoustic imaging camera to detect compressed air leaks. In the trial, Red Current Ltd initially tested the acoustic imaging service on a small sorting machine. The results were striking:
- Identified leaks and defects: Multiple leaks were detected, quantifying over £1,000 in potential annual energy savings.
- Downtime prevention: Several defects discovered during the survey could have caused significant downtime if left unresolved. This benefit highlighted the dual advantage of energy savings and enhanced equipment reliability.
- Client feedback: Impressed by the results, the client rolled out the acoustic imaging surveys to other sites with similar equipment.
How are the cost savings calculated?
The Teledyne FLIR Si2 Pro has built in cost calculation capability. For example, with compressed air leak detection, as long as we enter in the kWh energy price and distance from the leak source, the camera does the rest. By measuring the intensity of the sound and comparing the distance from the sound source, the camera's onboard analysis capability can automatically estimate the annual cost in real time.
Scaling Up: Larger Equipment, Bigger Savings
Building on the initial trial success, the service was deployed at another site with a similar sorting machine, approximately double the size of the first. The findings were even more impactful:
- Savings amplified: Leaks and defects identified translated to nearly £10,000 in potential annual energy savings.
- System efficiency: Improved performance and reliability were achieved with minimal operational disruption.
- Long-term planning: The data provided helped the client prioritise maintenance schedules and allocate resources effectively.
A tangible, measurable and impactful return on investment
The success of the acoustic imaging trial and eventual roll-out has meant that we can confidently demonstrate a tangible, measurable and impactful return on investment for clients with this innovative imaging technology.
Addressing compressed air inefficiencies by integrating acoustic imaging into your maintenance strategies, provides the following benefits:
- Energy savings: Significant reductions in wasted energy, contributing to sustainability goals.
- Cost efficiency: Quantifiable savings from reduced energy bills and minimised unplanned downtime.
- Enhanced safety: Early detection of leaks mitigates risks in sensitive and hazardous environments.
- Proactive maintenance: Supports data-driven decisions to prioritise repairs and optimise resource allocation.
- Operational reliability: Ensures equipment operates efficiently, reducing the likelihood of disruptions.
From manufacturing to healthcare, this service is a game-changer for industries relying on compressed air systems. By embracing advanced technology and innovative practices, businesses can unlock new levels of efficiency, safety, and profitability.
For production managers, operations managers, energy managers, and others focused on optimising resources and ensuring equipment reliability, this solution is not just an option — it’s a necessity.
Please contact us if you require a sample acoustic imaging report for compressed air leak detection.
