THE CLIENT

Ice River Springs, a Canadian manufacturer of PET plastic containers with multiple facilities across North America.

THE SITUATION

Ice River Springs made the decision to retrofit their Halton Hills high pressure bottling line, including taking on a compressor upgrade. Since CRU AIR + GAS was brought in after management had decided to proceed with the project, our team strongly recommended that a Save On Energy Audit Funding Project was conducted before any retrofit decisions were finalized. Doing so would reveal what the current energy consumption footprint of the existing system was and what it would be with the new equipment through an AIRMASTER+ simulation.

THE AUDIT

CRU AIR + GAS installed two VERIS True RMS power meters – one on each compressor. A CDI flowmeter was installed on the common header pipe to the plant to measure compressed air flow. Pressure transducers were installed before and after air treatment and at the end of the line to monitor plant pressure gradient. After the system baseline was established the new compressor energy profile was entered into AIRMASTER+ along with the new system consumption parameters. An energy efficient system simulation was done and new energy efficient case numbers were produced. Halton Hills Hydro had their 3rd party reviewer scrutinize all submitted data and the baseline and energy efficient cases were verified as accurate.

CRU AIR + GAS found that there were staggering consumption reductions that were possible with the retrofit project and our team carried out a simulation with the new compressor that was to be installed. A detailed RETROFIT project was formulated and submitted and, with the help of Halton Hills Hydro, the project was determined to bring a large incentive and reduction in the Halton Hills facility’s carbon footprint.

THE RETROFIT

Ice River Springs’ Halton Hills RETROFIT system consisted of the following equipment:

  • A new, oil-free, reciprocating air compressor.
  • A new high pressure bottling system line.

System pressure was lowered to the minimum required pressure that would allow production to run without issues or downtime.

What
Clients Say

“With CRU AIR + GAS’ help, we were not only able to operate year-round without any lost production time, but could start planning for a move towards optimizing our compressor system to maximize its energy efficiency.”
VP – Maintenance Planner
“[CRU AIR + GAS’] technicians are knowledgeable and available 24/7. Response times are less than an hour even in the middle of the night.”
HS – Maintenance Manager
“CRU AIR + GAS proposed a BOGE SLF 51-3 variable speed drive compressor project. When our LDC’s 3rd party reviewer tried to reduce our Save ON Energy Incentive, CRU AIR + GAS was relentless in arguing the case for the original estimated incentive. In the end, we secured a LARGER incentive than originally estimated. We couldn’t be happier with the final result!”
PL – Plant Manager
“[CRU AIR + GAS] don’t just come in and change spare parts when doing PM service. They examine the entire compressor system and make suggestions they feel will benefit our compressors in the long run. We highly recommend the CRU AIR + GAS team to any company looking for a trustworthy and knowledgeable compressed air service provider.”
RZ – Maintenance Manager
[CRU AIR + GAS’] local approach to the compressor industry provides us with fast, efficient service when we most need it, and their PM department ensures that our maintenance staff is made aware of upcoming service requirements for proper maintenance planning
JD – Corporate Engineer
“For almost 15 years, CRU AIR + GAS has been our primary compressed air service provider… they balance their focus on efficient compressed air production with our demanding production requirements.”
RC – Maintenance Supervisor
“With the only CEM, CEA, and Qualified AIRMASTER+ Specialist in Ontario, CRU AIR + GAS’ compressed air auditing was comprehensive and easy to understand. Our expectations were high and we were not disappointed!”
TS – Operations Manager

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