The ChallengeCompressor Rooms
The facility relied on a single 200hp compressor passing excessive oil downstream as operating hours increased. Maintenance demands continued to rise, while reliability concerns grew in a production environment requiring consistent air quality and pressure. Leadership needed a replacement strategy focused on uptime, efficiency and long-term operational stability.
The AssessmentA Roadmap to Savings
Brabazon conducted a comprehensive compressed air study, partially funded by Ameren Missouri, to identify cost-saving opportunities and performance improvements. The evaluation highlighted benefits from downsizing into a dual-compressor configuration using advanced control technology. Brabazon proposed replacing the existing unit with two 75hp compressors equipped with spiral valve technology, an electromechanical system matching compressor output to real-time demand with strong performance in challenging industrial environments.
The ResultVerified Savings Surpass Projections
Brabazon delivered a turnkey installation of the new compressors and configured the system to operate primarily on one unit, with the second supporting specific production processes. Sequencing and lead-lag rotation balanced runtime between both machines, while remote monitoring tracked energy usage, air consumption and system pressure with monthly performance reporting. The project produced verified annual energy savings of $35,000 from 652,470 kWh reduced usage and qualified for a $52,197.60 utility rebate. The total energy reduction equaled enough power to supply 52 homes for one year.
Beyond a Single Project Your Partner in Sustainable Efficiency
Brabazon supports manufacturers across the Midwest with compressed air studies, energy-efficient equipment upgrades and rebate coordination through regional utility programs. Each project focuses on improving reliability, lowering operating costs and supporting long-term performance through advanced technology and ongoing system insight.
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