Staircraft reduces installation costs and future energy consumption with a compressed air system designed around its new facility

The Challenge

Staircraft operates in the construction and building materials manufacturing sector, producing Stairs, Floors, Door kits and Profiles. As the business continued to grow, the company expanded into a new facility at Ansty Business Park following the purchase of a new totally automated MDF moulding and paint line.

With the new production requirements came a straightforward but important question: how could Staircraft provide the compressed air capacity required by the new facility while keeping installation and long-term operating costs under control?

The compressed air system needed to be designed around the demands of the new production environment, while the positioning of the equipment also had a direct impact on the overall installation cost.

The initial plan was to position the compressed air equipment in the centre of the factory. However, this would have meant extending the electrical infrastructure a significant distance from its existing location. For a growing manufacturing business, these additional costs would provide no operational benefit.

Staircraft therefore needed more than simply a compressor specification. It needed a compressed air partner who would look at the wider installation, challenge the initial plan where appropriate and design a system that made sense both operationally and financially.

The Solution

Air Kraft designed the compressed air system from the ground up, taking into account Staircraft's production requirements, available space, electrical infrastructure and the need for long-term energy efficiency.

One of the key recommendations was also one of the simplest.

Rather than positioning the compressed air system in the centre of the facility as originally planned, Air Kraft recommended moving the installation into a corner of the factory, immediately adjacent to the existing electrical infrastructure.

This meant Staircraft could avoid the unnecessary cost of extending the electrical supply into the centre of the building, while still providing the compressed air capacity required by the new moulding line.

The equipment

The completed system comprises:

• 2 × Atlas Copco GA75VSD+ variable-speed drive screw compressors
• 1 × Atlas Copco GA75+ fixed-speed screw compressors
• 6,000-litre, 11 bar air receiver
• Atlas Copco FX750 refrigerated air dryer
• Transair pipework
• EQ4-4 controller/sequencer
• Required filtration
• Oil-water separator
• Auto drain

The system was designed so that the fixed-speed compressor can operate at full load, with a VSD+ compressor varying its output alongside it according to demand for optimum efficiency. The compressors will alternate duty to optimise operation efficiency, maintain even running hours and align service visits.

This combination of fixed-speed and variable-speed technology provides Staircraft with a system capable of responding to changing production demands while keeping energy consumption under control.

Alongside the compressor equipment, Air Kraft also supplied the Parker Transair pipework system for the installation. This pipework solution is another factor that made Air Kraft stand out to Staircraft as their chosen compressed air supplier. Transair pipework is designed for quick assembly, offering a flexible and efficient installation process, which is exactly what Staircraft were looking for!

Air Kraft also provided a competitive upfront package based around Atlas Copco equipment, together with the Atlas Copco Guardian Service Plan and Extended Warranty package. This gives Staircraft ongoing support and maintenance following the installation, helping the compressed air system continue to perform as intended over the longer term.

The Results

The result was a compressed air installation designed not only to meet Staircraft's immediate production requirements, but also to consider the wider cost of ownership.

A comparison using data submitted through the Compressed Air and Gas independent trade association programme by Atlas Copco and a competitor indicates a significant difference in power consumption at a predicted flow rate of 200 L/s.

The performance comparison indicates that the Atlas Copco GA75 VSD+ operates at a lower power consumption than the competitor unit across the range of flows assessed, with the difference becoming more noticeable as flow increases.

Based on the stated assumptions, this represents a potential annual electricity saving of approximately £18,508.

Actual savings will depend on the facility's operating profile, compressed air demand, operating hours and electricity tariff. However, the comparison demonstrates the potential value of selecting energy-efficient equipment where compressors are expected to operate for thousands of hours each year.

Combined with the revised equipment positioning, Staircraft's installation was designed to address both the upfront cost of the project and the ongoing cost of operating the compressed air system.

Customer Perspective

For Staircraft, the value of the project extended beyond the equipment itself.

Production Director Dean Lucas at Staircraft highlighted Air Kraft's willingness to take the time to understand the project properly and find a solution that worked for the facility.

"Air Kraft were very approachable. The Air Kraft team took extra time to think the project through to provide a solution that we actually needed."

The installation also had to be coordinated alongside other contractors working on the new facility. According to Staircraft, Air Kraft's flexibility helped ensure the project stayed on track:

"The installation process was smooth, we trusted Air Kraft, they were flexible and accommodating working around other contractors to get the project done on time."

That relationship has continued beyond the original installation. Staircraft has since taken out service contracts with Air Kraft across multiple sites within the Staircraft Group.

"Any major issues and they arrive in quick response times swiftly and efficiently for call outs."

A compressed air system designed for the bigger picture

The Staircraft project demonstrates the importance of looking beyond compressor selection alone.By reconsidering the original equipment location, Air Kraft helped avoid unnecessary electrical installation costs. By combining fixed-speed and variable-speed Atlas Copco compressors with intelligent sequencing, the system was designed around Staircraft's changing production demands while optimising energy efficiency and helping to minimise ongoing operating costs. And by providing an ongoing Guardian Service Plan and Extended Warranty package, Air Kraft has continued to support the system beyond installation.

For manufacturers expanding their facilities or introducing new production lines, the compressed air system should be considered as part of the wider project - from initial layout and installation costs through to energy consumption, maintenance and long-term reliability.