Detecting Air Leaks, Saving €€€
Cygnum Building Offsite is one of Ireland’s?leading timber frame manufacturing companies. With?over 25 years of experience, 140 employees and 25 active sites, Cygnum is a specialist in making timber frames for houses, hotels, apartment blocks, care homes, schools and other public buildings.
By setting the standard for high-quality timber frames, Cygnum facilitates the building of exclusive and technically challenging structures. The team are continuously forging innovative solutions to help deliver their product – and as a result, leading-edge equipment is a must.
Cygnum’s facilities include an in-house technical engineering and design department, as well as a state-of-the-art manufacturing plant in Macroom, County Cork, capable of producing 1200 houses per year. In order to maintain the highest standards of output across the business,maintaining the efficiency of these facilities is essential – and that’s where RS Group were brought in to help.
The Challenge
With utility prices soaring, Cygnum needed to control their energy use in order to protect their budget.?However, after a survey of pneumatic equipment, Cygnum’s manufacturing plant was?suffering from undetected air leaks?that were worsening over time.
As of April 2022, the plant was losing approximately 593 litres of air a minute – at an estimated cost of €20,000 per year. With the rising?price of energy, this figure could be 35-50% higher?if the repairs went unmanaged.
Cygnum had been manually listening for leaks?during off-peak hours, which hadn’t revealed thefull extent of their energy losses. To provide the transparency required for critical, cost-saving decisions, a free ultrasonic air leak detection demo was arranged with RS Group.
The Solution
An expert RS engineer joined the Cygnum team on site to assess the compressor infrastructure. After a demonstration of the Fluke ii910 precision acoustic imager several leaks were found. The engineer then provided a sample report, outlining the potential savings the customer could expect from a full site survey.
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The potential ROI was immediately clear to Cygnum’s procurement manager, who said:?“I must admit that I was sceptical to start with, but the report we received from the?demo showed me in black and white that?there would be a saving here.”
The team then proceeded with a one-day air leak survey, where an RS expert joined a Cygnum maintenance technician on site to identify leaks and implement repairs.
The Outcome
By rectifying the air leaks revealed in the RS report, Cygnum reduced their energy costs and made?significant savings on compressed air resources.
The manufacturing plant reduced its carbon dioxide emissions by an estimated 20 tons per annum –?which is akin to taking 4.5 cars off the road for the?same period! Not only will this?help Cygnum to save an estimated €20,000 a year,?but they’re making strides to meet the environmental targets set out in their ESG goals, too.
That’s not all. Cygnum also benefitted from reduced?downtime, thanks to a preventative maintenance schedule which RS Group helped the team to successfully implement.
What are the benefits of air-leak surveys?
To find out more about how we can work with you, contact your RS Account Manager or email us at [email protected]