Executive Summary
A leading global electrical manufacturer, nVent often found its operations stalled owing to obsolete compression machinery and air leaks. After a thorough systems audit, the company chose to replace its 15-year-old backup machine of another brand with a state-of-the-art ELGi EG series air compressor. The move resulted in increased uptime, reliability, and productivity.
Overview of the Industry
The world is increasingly becoming more connected. Technologies such as 5G, artificial intelligence, and automation have become commonplace. Innovations in smart grids, industrial automation, and electric-powered transportation are completely disrupting and changing the face of infrastructure rapidly. As the world continues to transform dramatically, the energy demand is growing exponentially.
Out of all energy sources available to meet the world’s energy demands, electricity, in particular, is expected to outpace all other fuels and fulfill 21% of the global energy consumption by 2030[i]. The increased need for sustainability also drives the need for electrification as industries shift to electric power sources as an option towards decarbonising energy[ii].
With electricity offering energy efficiency and cost reduction, the electrification will increase the demand for all supporting products that aid in the generation, distribution, and protection of power.
Overview of the Company
nVent is a $2.1 billion, high-performance electrical company providing electrical connection and protection solutions. Boasting a dedicated team of 9,000 employees, the company manufactures and installs electrical products and solutions for equipment, buildings, and industrial processes. nVent products and solutions are available in three segments: electrical enclosures, thermal management, and electrical and fastening solutions, under the brand names CADDY, ERICO, HOFFMAN, RAYCHEM, SCHROFF, and TRACER.
Known for innovation, quality, and reliability, the company prides itself on connecting and protecting heating/electrical systems, consistently delivering bespoke solutions to commercial, industrial, residential, energy, and infrastructure customers.
nVent’s products protect their customers’ investments in facilities, helping them reduce the risk of equipment and process failure. Apart from simplifying installation and reducing downtime, nVent’s solutions also help improve productivity and reduce the total cost of ownership for their customers.
Customer Challenge
nVent manufactures a wide range of electrical products, including heat tracing systems, electrical enclosures, fastening systems, electronic packaging, and electrical protection systems. Their products find use in critical sectors such as military, aerospace, rail, telecom, and more. The manufacturing of these products needs a consistent supply of compressed air, which is necessary to produce finished goods that are 100% compliant with industrial and quality standards.
Further, at nVent, compressed air is required to run various operations in the manufacturing units, from assembly until packaging. Any deviation in the air pressure leads to an immediate impact on the production process, resulting in unavoidable downtimes. Any air leakage is detrimental to the manufacturing process and causes nVent to run a second trim machine during high demand.
When nVent signed up with Pattons, a US subsidiary of ELGi, on a four-year service contract for maintaining their air compressors, a baseline systems audit was performed. Results from the systems audit found that the customer was dependent on a 15-year-old backup machine from another brand during high demand. In addition, they also faced intermittent low-pressure issues and a 235 CFM leak load on the system.
The Solution
Pattons conducted a thorough air leak study at nVent’s facility, confirming the results of the audit. During this time, the existing backup compressor had critically failed, causing production downtime that necessitated the immediate installation of a new air compressor. Using the baseline audit information, Pattons fulfilled their compressed air needs by pairing their current ELGi EG 75VSD model sold in May 2018 with a fixed speed ELGi EG75 in June 2020 as a replacement for their old backup compressor from another brand.
Pattons also helped nVent with air monitoring, providing real-time information about each compressor remotely, tracking historical data, and moderated their facility for an extended period. Pattons configured the air compressors to run at optimal levels so that their fixed speed unit ran during the week while the variable speed unit ran as the lead machine during their third shift and weekends, resulting in energy savings.
Business Benefits
Pattons saved nVent $8,300 on non-preventive maintenance service calls where usual preventive maintenance/service agreements would not address the underlying issues. It also ensured:
Improved uptime: Before getting the new systems, nVent had many downtime issues throughout the year, requiring Pattons to visit outside of scheduled times.
Better reliability: With the new setup, nVent no longer makes emergency service calls since their new equipment is more reliable.
Enhanced profitability: In addition to the cost savings on non-preventive maintenance service calls, nVent increased overall productivity, translating into more profits.
Conclusion
“Our facility is highly equipment driven, and we rely on our equipment to produce the products needed by our customers. Prevention has and always will be the main goal, but it’s how you react when issues arise that you didn’t plan for is where it counts the most. Pattons has proven time and again that they continue to operate with that “customer first” mentality.”
“In the highly competitive manufacturing industry, there is value in sustaining a partnership for 17 years. We built our partnership for years on trust in service and great personal relationships. Erik Shaw, our system specialist, is owed a lot of that credit as he has exemplified the Pattons organisation for our facility. We would strongly recommend partnering with Pattons for any compressed air needs, whether it be service, maintaining the current system, or taking it to the next level, Pattons can help.” - David Widman, Maintenance and Facilities Manager.
At ELGi, we step into our customer’s shoes to develop solutions that best fit their business needs.
By ELGi
5 min read