Graphic Village had been growing by leaps and bounds by acquiring well run, solid companies in the graphic arts field. With two additional acquisitions, Graphic Village had become the largest independent print marketing company in the region. Graphic Village had just purchased an existing 153,000 square foot industrial building not far from their current location in Blue Ash. They planned to consolidate the current operations and the operations of recently acquired Multi-Craft Litho, a print graphics company, and CTS Packaging, a folding carton company.

All three plants to be moved to the new location had their own compressed air systems consisting of air compressors, air dryers, and receiver tanks. The new location where they were moving possessed an already installed extensive black iron compressed air piping system that was well equipped with ceiling drops with valves. The plan was to install drop ceilings in the production areas at the new location.

Graphic Village wanted to use existing compressed air equipment and any existing infrastructure where possible to minimize costs while not sacrificing their desire for energy efficiency, dry air, and reliability.

Industrial Air Centers implemented the action steps described below that enabled GV to consolidate all three plants with minimum disruption. The result was that revenue generating equipment was off line for a very short time minimizing loss of cash flow during the consolidation.

IAC surveyed the equipment demand for air in each individual plant. Model numbers, capacities, voltage, and condition of each piece of existing compressed air equipment was recorded. Decisions were made if any of the existing compressors might be used at the new location.

Minimum and maximum compressed air demand loads at each plant were observed by IAC or communicated to IAC from plant personnel. The results showed that if each plant ran at its own maximum supply capacity, and then these capacities were totaled into one, a one hundred horsepower compressor was required to meet the flow. However, it was factored that each plant had inefficiencies in operation, and that the new consolidated plant could run on 75% of the total capacities of the three plants combined.

IAC installed a 75HP rental compressor to pressurize the existing piping distribution system, then identified and repaired inherited leaks from the prior tenant.

With an adequately sized (by estimate) rental compressor in place, and with GV’s plant consolidation on a fast track for completion, IAC worked in coordination with the drop ceiling installers, electricians, and production equipment installers. Infinitytm aluminum compressed air pipe was hung by IAC from the existing header outlets directly over head and through the drop ceilings directly vertical to the inlet of the production equipment. This with single drop electric and other utilities provided GV with a clean looking installation for the production equipment.

After all production equipment was relocated and online, IAC’s Energy Management Team installed a data logger on the 75HP rental compressor. The study concluded that though a 75HP compressor could run the plant, it would not allow adequate capacity for potential future growth in demand.

It was decided to install one new Elgi EG Series 100HP Variable Speed Drive Compressor along with a matching new 500 scfm refrigerated air dryers. Former CTS Packaging’s existing 25HP and 50HP compressors were installed as backup to the new unit. Two existing receiver tanks and one mist eliminator were utilized.

IAC submitted a Duke Smart Saver Incentive application for GV resulting in a $5000.00 rebate. The variable speed drive will save GV up to 35% off their compressed air related energy bill.

Dubbed by Graphic Village as “The Print Shop of the Future,” the ultra-modern facility was built to attract both employees and customers. “We want to attract and retain the best employees, to create a great place to come to work,” Eric Kahn, CEO says. “And we want our customers, when they walk in, to say, ‘Wow, I want to do business with this company.’”

IAC: Eric, the quality in your building goes all the way back to the compressor room. Thank you for your business.