Lower life-cycle costs

Energy costs taken over the lifetime of any compressor add up to many times that of the initial capital cost, which can make any purchase price difference a false economy. Efficiency and reliability are vital in the production of compressed air and KAESER achieves these objectives with quality, durable components that are built to last.
Energy-saving KAESER rotary screw compressors can help users to significantly reduce their compressed air costs.

Energy saving controllers SIGMA CONTROL and SIGMA CONTROL BASIC

The SIGMA CONTROL automatically regulates and monitors the compressor. It is a robust PC-based industrial computer with real-time operating system and update capability. System operating status can be viewed at a glance via user-friendly ‘traffic light’ LEDs. The four-line plain text display, touch keys and icons ensure ease of operation.
In case of an alarm the safety shutdown sequence immediately switches the compressor off. The SIGMA CONTROL offers the possibility of Dual, Quadro and Vario Control modes and the most efficient mode can be determined directly onsite using the programmable compressor duty cycle display feature.
Interfaces are provided as standard for connection of a modem, a second compressor in base load sequencing mode and for connection to data networks.

Energy-saving compressor airend with SIGMA PROFILE rotors

A specific drive power can be used to turn a smaller airend at high speed or a larger airend at slow speed. Larger, lower speed airends are more efficient and deliver more compressed air for the same drive power.
This is why KAESER manufactures low speed airends with optimised rotor profiles. Every KAESER rotary screw compressor quickly pays for itself through significant savings in energy costs.

The KAESER SIGMA PROFILE

Developed by KAESER and continually enhanced ever since, the KAESER SIGMA PROFILE brings power savings of up to 15 percent compared with conventional screw airend rotor profiles.
All KAESER rotary screw airends feature this energy-saving rotor profile and are designed to ensure maximum energy-efficiency.
The generously-sized, precision-aligned roller bearings and close-tolerance machining guarantee long service life and outstanding reliability.

Drying

The atmospheric air drawn into a compressor is a mixture of gases that always contains water vapour. However, the amount of water vapour that air can carry varies and is mostly dependent on temperature. As air temperature rises – which occurs during compression – the air's capability to hold moisture increases also. When the air is cooled its capacity to hold moisture reduces, which causes the water vapour to condense. This condensate is then removed in the centrifugal separator, or the air receiver, downstream from the compressor. Even then, the air can still be completely saturated with water vapour. This is why, as the air cools further, significant amounts of condensate can accumulate in the air distribution piping and at take-off points. System failure, production downtime and costly service and repair work are therefore unavoidable without additional air drying.

Filtration

On average, a compressor sucks in up to 190 million particles of dirt, hydrocarbons, viruses and bacteria with every cubic meter of atmospheric air. The compressor itself can only remove the larger dirt particles and the majority of the contaminants remain in the compressed air. This means that for most applications careful treatment of the air is necessary: Clean, quality compressed air maximises air-tool service life, ensures that pneumatic machinery and control systems operate at the peak of their performance and keeps pipes & valves free from contaminants. It therefore not only reduces service, maintenance and repair costs, but can also reduce initial investment costs.

Compressed Air Storage

Due to its storage and buffer capacity, the air receiver plays a key role within a compressed air installation: It provides capacity during periods of peak demand and is often used to separate condensate from the compressed air. Therefore, it is important for the receiver to be correctly sized for the specific system, to be resistant against corrosion and to have long inspection intervals. Air receivers from KAESER meet all of these requirements.
On-site installation should also be made as simple as possible: Every KAESER air receiver is delivered pre-assembled and ready for installation with the complete EasyFit receiver system.

Air-main Charging Systems

Compressed air treatment systems are designed for a certain rate of air flow which, when the system is operating at full load, pushes against the pressurised air in the air distribution network. However, should this resistance not be present, for example during periods of low load or downtime, it is possible that dryers and filters may be overwhelmed by the sudden surge in airflow that occurs when the system re-starts. Air-main charging systems prevent this from occurring. They not only ensure consistent compressed air quality, but also enhance system reliability and significantly extend the service life of air treatment equipment.

Condensate Technology

Condensate is an unavoidable result of air compression. It is a chemically aggressive fluid that mainly consists of water, but also contains oil and dirt particles (e.g. rust). If not reliably drained off at all collection points, it can cause operational disruption and severely damage the compressed air system through corrosion. Experience has shown that float controlled drains become unreliable over time and that time controlled drains can be a source of considerable air loss. The electronic level-sensing controlled ECO DRAIN provides the perfect solution. 
Water resource legislation stipulates that contaminated water must be treated to achieve prescribed safety levels regarding purity. KAESER’s AQUAMAT condensate treatment systems do precisely that: They ensure that contaminant levels are kept well within regulation limits (max. 10 or 20 mg/litre for hydrocarbons for example).

Modern, Efficient Air Tools and Equipment   Quality tools and compressed air systems from KAESER Tool quality plays a key role in how effectively a task can be carried out. This particularly applies to compressed air tools, as they need to operate in close harmony with the compressor to achieve maximum efficiency and produce perfect work results. KAESER provides a comprehensive range of high quality compressed air tools and specially tailored turnkey compressors to meet all of your needs. For example, a single operator can work efficiently and independently on a construction site using a versatile KAESER compressor and tool combination. Compressed air tools from KAESER KAESER’s comprehensive range of air tools consists exclusively of high quality, premium products designed for professional use. Coupled with low noise and minimal vibration, all KAESER air tools are easy to operate and provide outstanding reliability and performance to achieve perfect work results. SIGMA AIR UTILITY - just buy the air you need   How much does your compressed air cost? The cost of each kilowatt-hour of power consumed, each cubic metre of water used and each kilometre over which goods and materials are transported are fundamental factors in determining actual operating costs. In the case of compressed air - one of industry's prime energy sources – approximately 90% of users are unable to give an accurate figure for the cost of each cubic metre used. This is hardly surprising, as the cost of self-produced compressed air varies greatly with circumstances and to extract a cubic metre price from the total costs over the amortisation period of the air supply system is not easy. The calculation not only includes the fixed and operating costs but also has to take less tangible figures into account such as the proportion of labour costs for personnel who are only partially or occasionally involved in the air supply system, including training activities. However, SIGMA AIR UTILITY from KAESER provides optimum cost transparency.     Reduced costs Compressed air production, treatment and usage often require considerable use of valuable resources. This doesn’t necessarily have to be the case however, as SIGMA AIR UTILITY frees up these resources so that they can be put to more productive use elsewhere.     Reduced air costs SIGMA AIR UTILITY is highly cost-effective, as you pay only for the air you use. The very latest advances in air system technology also ensure maximum air production and energy efficiency.     Latest technology Every SIGMA AIR UTILITY compressed air system features the very latest technology to ensure optimum dependability and efficiency. Key components are also updated with the newest versions if they enhance performance or are of technical advantage.     Maximum reliability Sigma Air Utility systems are linked via KAESER’s ‘Teleservice’ facility to the KAESER Service centre. This capability enables preventative maintenance measures to be taken and ensures optimum use of material and human resources. The result: maximum system dependability.     Maximum availability KAESER’s ‘Teleservice’ facility and system-specific back-up measures ensure maximum compressed air availability. If necessary, KAESER’s experts can seamlessly maintain air delivery even during load transfer from existing to new components, or to a completely new air supply system.