Festo

Energy Saving Service
Frequently Asked Questions

 




Why is the energy consumption of a machine so important for EUs?
With the price of energy continually rising, steps must be taken to avoid the inefficient use of pneumatic components. Each year consumption figures have become more and more important. Therefore, it is ever increasingly critical for end users to seek out ways to eliminate waste from their processes in order to remain competitive and profitable and to document the energy efficiency of their products. Energy costs are a major incentive to analyze and improve performance. What is hampering many companies is the lack of our expertise as manufacturer of pneumatic components, appropriate technologies and techniques for the accurate measurement of compressed air consumption and, more importantly the skills to analyze the data and provide effective action plans.

How does the Festo Energy Saving Service help EUs?
The Festo Energy Saving Service is an extensive evaluation of all pneumatic components on each machine within a factory. As compressed air specialists, we help the end users first understand and then improve energy consumption at the individual machine level. During an Energy Saving Service of Festo pneumatic machines and applications are evaluated and precise consumption figures are measured, providing the documentation essential to ISO 14001 compliance. This evaluation ranges from fittings and quick connectors to valve terminals and actuators. Every detected leakage and weak points are documented and suggestions for improvements are given. Leakages are eliminated on a piece-by-piece level by in-depth examination of all pneumatic devices. In addition, every pneumatic component is checked for correct sizing and application to insure optimal efficiency.

What exactly are the benefits of the Festo Energy Saving Service for EUs?
For the end user the savings can be impressive. Experience shows that by identifying and eliminating leaks, and optimizing the usage of compressed air of pneumatic machines or applications, plant operators can expect to save up to 35% of energy costs. Reductions of compressed air up to 55 % were already achieved during some projects. With savings of that order, a full optimization and maintenance exercise will pay for itself within two years – often considerably quicker. The improved machine performance and throughput through increased pressure stability, the reduction of maintenance costs or the avoidance of new compressor purchases are oftentimes side effects.

The Festo Energy Saving Service spans the following steps, all carried out by pneumatic specialists using state of the art, calibrated and tested measuring equipment and advanced analysis software:

  • Detailed evaluation of all pneumatic components on each machine or application within a factory by a Festo Energy Savings Engineer
  • Measurement of consumption figures in the main line during running, standby, and off modes. If the machine or application requires a more detailed evaluation (maybe consumption figures of parts of his machine are of interests) additional measurements can be done at different test point locations.
  • Leakage detection via ultrasonic diagnostic equipment
  • Follow up measurement to complete cost savings calculations
  • Comprehensive report summarizing all located leakages and points of improvement, energy cost per year for running the machine and cost savings achievable through the service

What are the basic requirements for project consideration?
The successful conductance of the Festo Energy Saving Service requires a little assistance of the customer. Since we measure the compressed air needs of machines in different operational modes with sensors inserted into the pneumatic lines we need the customer’s assistance not only for the installation and de-installation of the sensors, but also to run the machine in different modes.

How many machines can be evaluated in one project?
Dependent on project preparations several tests can be performed during one day. In an ideal case machine operation is flexible and all adapters, manpower and tools are in place. In such a scenario more than one ‘typical machine’ can be evaluated during one day. In some cases less than one machine can be evaluated, e.g. if target application is huge and performance of the project depends strongly on production schedule.

How much downtime is required to install/remove the test equipment?
Experience shows that installation and removal of the test equipment takes approximately 20 - 30 minutes. This does vary from application to application.

Do customers need to use Festo components exclusively?
No, the energy savings service can be used on machines with any pneumatic manufacturer’s components.

What if I want Festo to do this service on all my machines on a regular basis?
This is possible as a part of a service contract.

What is the difference between the Festo Energy Saving Service and an Air Audit conducted by a compressor room company?
The Festo Energy Saving Service is conducted on the demand side of the compressed air system. This means that no compressor room evaluation and no air distribution system evaluation will be included.
© 2008 Festo Corporation