Aircare installs fully integrated compressed air system at Cosworth’s state-of-t
October 21, 2016
Gardner Denver distributor Aircare Compressor Services (Aircare) has delivered a bespoke compressed air solution at an innovative new facility for Cosworth, a leading manufacturer of electronics and powertrain products.
The company’s Advanced Manufacturing Centre (AMC) in Northampton is fitted with the latest manufacturing systems, enabling Cosworth to supply high-performance engines for premium sports car manufacturers, as well as offer a ‘one-stop-shop’ for products and technologies for the automotive, motorsport and performance aftermarket industries.
Aircare fitted a comprehensive compressed air system at the site – currently delivering 420cfm – optimised for energy efficiency, comprising air generation, management, treatment and even a heat recovery process.
The 38,000ft2 facility is the result of a £22m investment supported by the company’s shareholders, the Department for Business, Innovation & Skills, local government and Northampton Borough Council.
Mark Tiana, Head of Programmes at Cosworth, explains: “Compressed air is an absolutely critical element of our operations; without it, our business would not function. We have worked with Aircare for the last five years, with the company providing equipment, pipework and expert service and maintenance to four of our existing manufacturing sites. When it came to selecting a supplier to deliver a fully integrated compressed air system for our state-of-the-art Advanced Manufacturing Centre, there was no question that Aircare were the best partner for the job.
“Our on-site automation and cutting edge technology requires a very high volume of compressed air. For instance, the AMC is the only site in the UK to offer plasma ion coating, a technology that reduces engine friction and weight, subsequently lowering CO2 emissions. This high-performance technology depends on a consistent supply of high-quality compressed air to operate effectively, so we had to have complete confidence in the system specified.”
Aircare supplied two CompAir L75 rotary screw speed-regulated air compressors and one L75 fixed speed unit, as well as fitting two large air receivers, a refrigerant dryer, filtration and a condensate management system. The company also integrated the compressed air control interface into Cosworth’s building management system, and installed a ducting system to recover the otherwise wasted exhaust air generated by the compressors into the factory to provide heating.
“CompAir is a highly-regarded brand in the compressed air industry,” says Mark, “so we knew we could trust this technology. Of the three compressors installed, the two variable speed units deliver a consistent supply of compressed air for our day-to-day needs, with the third, fixed speed model acting as a stand-by machine that comes online to meet increased demand.”
Mark continues: “Aircare have been very supportive throughout the whole process. They are always available to answer any technical queries and to provide ongoing service and support, meaning you can be assured that you’re investing in an efficient and reliable solution.”