Casalgrande Padana adopts Kaeser 4.0 technology

Following installation in October 2016 of the new compressed air system supplied by Kaeser Compressori, the Bologna-based Italian subsidiary of the renowned German multinational, the Casalgrande Padana facility in Dinazzano has reported 15% energy savings and the ability to constantly monitor production and compressed air consumption by means of a predictive maintenance system.

To meet the needs of the facility, which produces 22,000 square metres of tiles a day, an energy audit was first conducted using the ADA KESS system to determine the specific consumption of the existing plant. Next, two machines were installed (a DSDX 305 SFC 160 kW variable speed screw model and a DSDX 245 132 kW fixed speed model) in place of the four existing 110 kW units, two of which are now used for backup. The plant has also been equipped with three TF340 thermal mass dryers for the treatment system.

The room is managed using a Sam 4.0 control unit which is capable of maintaining the system’s pressure as close as possible to that required by user devices, estimated at around 6.4 bar. A calculation algorithm takes account of the historic consumption levels of the factory and projects the behaviour of the system in the immediate future on the basis of the stored data. The aim is to ensure the highest efficiency and to allow for predictive maintenance so as to avoid machine stoppages and unexpected need for servicing. Use of the variable speed machine with control unit management allows the pressure to be kept constant rather than fluctuating, bringing clear advantages in terms of consumption.