Operations and maintenance in the glass container industry

Compressed air is a significant electrical end-use at most manufacturing facilities, and few industries utilize compressed air to the extent of the glass container industry. Unfortunately, compressed air is often a significant source of wasted energy because many customers view it as a low-maintenance system. In the case of the glass container industry, compressed air is a mission-critical system used for driving production machinery, blowing glass, cooling plungers and product, and packaging. Leakage totaling 10% of total compressed air capacity is not uncommon, and leakage rates upwards of 40% have been observed. Even though energy savings from repairing compressed air leaks can be substantial, regular maintenance procedures are often not in place for compressed air systems. In order to achieve future savings in the compressed air end-use, O and M programs must make a special effort to educate customers on the significant energy impacts of regular compressed air system maintenance. This paper will focus on the glass industry, its reliability on compressed air, and the unique savings potential in the glass container industry. Through a technical review of the glass production process, this paper will identify compressed air as a highly significant electrical consumer in these facilities and present ideasmore » on how to produce and deliver compressed air in a more efficient manner. It will also examine a glass container manufacturer with extremely high savings potential in compressed air systems, but little initiative to establish and perform compressed air maintenance due to an if it works, don't mess with it maintenance philosophy. Finally, this paper will address the economic benefit of compressed air maintenance in this and other manufacturing industries.« less