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The production use of compressed air is prevalent throughout the entire plant, from air cylinders, dry product unloading and cooking processes. As the facility grew over the years the compressed air system underwent few changes other than the addition of more compressors. Production managers complained of equipment downtime, due to low air pressure. Operators complained of not being able to keep air pressure high enough to satisfy plant demand, 115 psig. Kal Kan thought they needed more air, but additional space for compressors was not available. IAC/PTG was asked to conduct an air audit to examine their system.

Audit Findings
• The plant was operating at an average of 102 psig.
• The plant experienced pressure fluctuations of 20 psig.
• Existing compressor capacity was sufficient.

  Recommendations

• Install a flow controller.
• Add additional storage.
• Adjust compressor controls

  Benefits

• Stabilized air pressure within 2 psig.
• Lowered plant operating pressure to 95 psig.
• Plant production increased 10%.
• Energy costs from compressor room dropped 14%.