Compressed air without risk - for maximum safety in the chemical industry for sensitive processes
In the chemical industry, every component counts - especially when it comes to the compressed air supply. In sensitive and often safety-critical applications, contaminated compressed air can have serious consequences: toxic reactions, corrosion, unstable end products, or costly production downtime.
As a long-standing authorized dealer for KAESER compressors, FILCOM GmbH offers a comprehensive portfolio of oil-free, high-availability compressed air systems precisely tailored to the requirements of the chemical industry. Customized solutions ensure that processes from product drying to conveying and control to nitrogen generation are supplied with high-quality compressed air at all times. This prevents incalculable risks in advance and ensures the safe, efficient, and economical operation of compressed air systems.
Schill+Seilacher
Schill+Seilacher GmbH is a traditional, medium-sized company in the chemical industry. Founded in 1877, the company specializes in the production of industrial process additives. The Böblingen plant and development laboratories focus primarily on chemical active ingredients that simplify both the production and further processing of technical textiles, chemical fibers, cosmetics, industrial and cosmetic cleaners, as well as leather and paper. For example, insulation mats in car engine compartments are treated with Schill+Seilacher flame retardants. Shower gels contain surfactants that increase lather.
With six independent production sites and approximately 900 employees worldwide, Schill+Seilacher is one of the most successful companies in its industry.
Challenge
A customized compressed air station, perfectly suited to the respective application? This is standard at FILCOM, but still not a given for many. The technical and economic performance of a new compressed air station must be clearly designed and calculated from the outset. Only then can it precisely meet all expectations in practice. After all, high-quality, oil-free, and reliable compressed air is a huge challenge for applications in the chemical industry. Critical manufacturing processes often involve toxic, corrosive, and unstable products that come into direct contact with compressed air. Costly production downtime and rejects can only be avoided if clean compressed air is reliably available.
Solution statement
- The old piston compressors, which had been in use at Schill+Seilacher until 2007, had reached the end of their service life.
- Urgent action was needed to improve energy efficiency and reliability for the plant's compressed air supply.
- Seeking the best technical and most cost-effective solution, Schill+Seilacher contacted FILCOM GmbH.
- FILCOM GmbH's proposals regarding investment, operating and maintenance costs, as well as reliability, were reviewed and evaluated by the customer. The KAESER systems won Schill+Seilacher over.
- Thanks to the high efficiency of the Super Premium Efficiency motors, the new compressors operate with exceptional energy efficiency.
- Stable pressure dew points are ensured thanks to the use of KAESER's high-quality, industrial-grade SECOTEC refrigeration dryers.
Customer benefit
- FILCOM's setup includes two KAESER ASD-32 screw compressors, three energy-saving refrigeration dryers, various filters, and two compressed air receivers.
- Given the required compressed air volume, compressed air quality, and reliability of the equipment, the choice of KAESER ASD series screw compressors in combination with the energy-saving refrigeration dryers proved to be the most reliable and cost-effective solution.
- The KAESER SIGMA CONTROL 2 control unit, integrated into the screw compressor at Schill+Seilacher, coordinates compressed air generation and consumption.
- This intelligent control system, based on an industrial computer, helps prevent inefficient energy consumption, especially during partial load operations. The control unit is linked to interchangeable input and output modules.
- When implementing the concept, Schill+Seilacher opted for KAESER rotary screw compressors to prevent unplanned production downtime, which is ultimately a costly undertaking.
- Process continuity is a key focus and extremely important.