Air Leak Survey

Value add air leak surveys deliver monthly energy savings of £4,000

The challenge

A global leader in metal packaging wanted to lower their energy usage by identifying air leaks on their line. They wanted to implement an ongoing, proactive air leak survey program but were concerned about the ongoing outsourcing costs.

The solution

ABCO conducted a three-day air leak survey, alongside pneumatics expert Festo. Instead of just fixing the leaks, ABCO proposed a comprehensive training package for the on-site engineering team so that they could not only prevent further leaks, but also conduct future leak surveys themselves.

Results

This customer can now continuously improve plant performance with onsite air leak surveys, keeping outsourcing costs minimal and enabling them to react quickly when an air leak is suspected.

This project delivered a 17% reduction in compressed air usage
Following the initial air leak surveys the customer recorded a monthly energy saving of £4,000

“Our value add services are designed to improve energy efficiency and deliver tangible cost reductions and this project showcased just that. “More importantly, it showcased that ABCO searches for the right solution for the customer rather than the solution that best suits us – instead of insisting all future air leak surveys were outsourced to us, we training the team to conduct them inhouse. This truly demonstrates our commitment to long term partnerships.”

James Gibson

Managing Director, ABCO

“The foundation of knowledge given to the engineers has allowed us to create a sustained improvement in our energy usage and also helped encourage the teams to seek further improvements on the line.”

Jonathan

Asset Manager

Case Studies

Air Leak Survey

Value add air leak surveys deliver monthly energy savings of £4,000

Urgent PPE Supplies

£100k per day in revenue safeguarded for major construction materials supplier

A leading supplier of construction materials, urgently needed 250k certified face masks so their teams could support government efforts to build temporary hospitals and testing centres during COVID 19. Let down by their usual PPE supplier, they faced revenue losses of £100k per day.The masks needed to be genuine and fully certified and they were needed within a 48-hour timeframe.

5S Workshop

A traceability-led 5S workshop for major automation specialist

A team of automation engineers needed a 24-man workshop that could hold all the tools required to perform maintenance across the processing site of a major UK retailer. The workshop needed to include specific tool kits that were easy to transport, as well as storage and shadow boards that provided total traceability and ease of auditing.

Vending Solutions

Vending machine management delivered £14,000 annual saving for major manufacturer

A leading packaging manufacturer had an existing vending solution, supplied by a major competitor. Service standards began to slip and costs began to creep up. Replenishment was inconsistent, the quality of data was poor and unapproved product swaps were added to vending inventory.

All case studies