From Reliability to Efficiency: Evolving with Our Customers for 25+ Years
The Challenge
A long-standing Maziak customer, manufacturing pre-cast concrete fencing products, operates near our headquarters in Wellingborough, Northants. They have been with us for over 25 years, benefiting from local, cost-effective support and services such as planned preventative maintenance, air leak surveys, written schemes of examination, and compressed air safety guidance. The site relied on four air compressors serving different operations and areas. Historically, they preferred industrial piston compressors—a common choice for harsh, dusty environments. However, one of these compressors, supplied and installed by Maziak in 2009, recently failed beyond economical repair. They asked us to provide a replacement solution.
The Solution
While a like-for-like replacement would have been the obvious choice, our engineers took a more strategic approach. After a detailed site survey, we assessed the current compressed air system and explored future requirements. Factories often adapt their systems over time, and a fresh review can uncover opportunities for efficiency and cost savings. Instead of another piston compressor, we recommended an Atlas Copco variable speed rotary screw compressor. This advanced solution offered several advantages:
- Higher Output: 20% more capacity than an equivalent piston compressor.
- Consolidation: A G7VSDFF 7.5kW model could replace the output of two piston compressors, streamlining operations.
The Results
- Lower Service Costs: Two compressors replaced by one modern unit.
- Energy Savings: One 7.5kW motor instead of two 5.5kW motors.
- Improved Air Quality: Integrated dryer and filter reduce contaminants and help prevent future leaks.
- Enhanced Work Environment: Significantly quieter operation.
Customer Feedback: "We couldn’t believe how quiet it is."
