Johnson Electric
- Seven aging compressors replaced with one right-sized Kaeser unit
- 440,000 kWh saved annually, with $58,412 in SaveONenergy rebates secured
- Turnkey supply, installation, pipework, ventilation, and BMS integration
- 5-year Bumper to Bumper warranty, no maintenance surprises
Engagement Details
Before recommending anything, Kyle proposed a 9-day Air Demand Analysis (ADA) to get the full picture. The study captured:
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CFM volume
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System pressure
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Air receiver storage capacity
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kW/hr energy consumption
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Energy cost per kW
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Compressor control performance
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Machine suitability and sizing
The data, analyzed by Air Solutions Canada's application engineering team, was eye-opening. Armed with real numbers, Kyle designed a solution that replaced two aging 75kW (100hp) compressors with a single 128kW (175hp) Kaeser CSD175T, complete with an integral refrigerated air dryer built into its compact, super-silent cabinet.
Technical scope:
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Supply and installation of one Kaeser CSD175T, 175hp rotary screw air compressor with integrated refrigerated dryer
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Tele-handler lift and placement of the 5,000lb compressor package to the second floor
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TSSA-approved Kaeser Blue Smart Pipe pipework installation
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Design, supply, and installation of a heating and ventilation sheet metal ductwork system
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Positional louvres for winter heat reclaim to adjacent spaces
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Full integration of compressor controls into Johnson Electric's existing building management system (BMS)
The Result
The transformation was significant across every critical dimension that mattered to Johnson Electric.
A 55kW energy reduction, translating to approximately 440,000 kWh saved annually, qualified the project for a $58,412.50 SaveONenergy incentive rebate secured entirely by Air Solutions Canada on the client's behalf.
The Kaeser's Bumper to Bumper 5-year warranty eliminated unplanned breakdown costs and removed ongoing maintenance surprises from the equation. The integrated dryer reduced the compressor station footprint, freeing up valuable floor space in an area where every square foot counted. With the addition of a properly sized, energy-savvy system in place, the risk of a single compressor failure cascading into a plant-wide pressure event was eliminated.
Johnson Electric's internal CAPEX approval process is stringent. This project got the green light because the business case was airtight: a documented SaveONenergy rebate, lower operating and maintenance costs, and a measurable improvement in system reliability and compressed air quality.
Related products
Compressors
Our range of air compressors includes reciprocating piston, oil free, and oil injected rotary screw air compressors, from 3hp up to 700hp, and everything in between. If you do not know what you are looking for, we can assist with that too.
Dryers
Selecting the right dryer and filtration to ensure your facility receives clean, dry compressed air consistently, depends on many things. Our clean air selection process is based around ISO 8573.1 quality class standards.
Pipe Work
Our mechanical team is TSSA certified to perform all types of pipe work. Stainless steel, copper, aluminum, galvanized and black steel pipe are available for supply and installation. Our team also specializes in ductwork, machinery moving, and rigging applications.
Controllers
Kaeser's Sigma air Manager, SAM 4.0 provides complete system management for air compressors, blowers and vacuums, from a large easy to read screen, with remote access options.
The ultimate guide on rightsizing your compressed air system
Choosing the right compressed air system is crucial to minimize the total cost of ownership. How do you calculate the air demand in flow rate (CFM) and pressure (PSIG), what's the power requirement (V), and how does that translate in a compressed air system with one or more compressors (hp)?
Download our Comprehensive Guide for Choosing the Right Compressor Size!