Foul Play at an Injection Molding Manufacturer Site

An injection molding manufacturer was experiencing repeated failures of an air compressor that was critical for production. The compressor had been cleaned the year before at a cost of $35,000, and the cooling water chemical treatment provider assured the manufacturer that adequate treatment was in place to protect the machine. The air compressor had become unreliable again and it was suspected that fouling due to scaling was the root cause.

Customer Goals:

  • Provide a closed-loop pump, heat exchanger, and piping system to serve the air compressor.
  • Connect the closed-loop system to the existing open-loop cooling source.
  • Provide permanent water treatment on the closed-loop side.
  • Design, procure, and fabricate a skid-mounted system that required minimal time to install and commission.

Solutions:

  • Provided a closed-loop pump, heat exchanger, and piping system to serve the air compressor.
  • Connected the closed-loop system to the existing open-loop cooling source.
  • Provided permanent water treatment on the closed-loop side.
  • Designed, procured, and fabricated a skid-mounted system that required minimal time to install and commission.

Results:

  • The new system provides controlled water quality to protect the air compressor internal from fouling and scaling.
  • The new system provides a means of heat exchange that allows the open-loop system to be operated at an economical level of water quality.
  • The new system allows for easy maintenance and service to the modular design.
  • The air compressor has achieved a level of reliability and performance never before experienced at the facility.

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