Mann+Hummel's Air System Overhaul: A Case Study in Receiver Tank Impact

Case Background: Mann+Hummel, a global leader in filter manufacturing, faced persistent issues at their factory with excessive moisture and unstable air pressure. This led to as many as 20 air-related breakdowns daily, severely impacting production efficiency and product quality, and leaving the maintenance team constantly overwhelmed.

Solution and the Role of Air Receiver Tanks: Pattons and ELGi partnered to comprehensively overhaul Mann+Hummel's compressed air system, which included the installation of Airmate wet and dry air receiver tanks.

The air receiver tanks played several crucial roles in this solution:

1. Pressure and Flow Stabilization: The receiver tanks absorbed pressure fluctuations caused by compressor start-stop cycles, ensuring a stable and consistent supply of compressed air. This was vital for Mann+Hummel's precise manufacturing processes.
2. Moisture Removal: Inside the receiver tanks, hot, humid compressed air was allowed to cool, causing moisture to condense and separate from the air. This significantly reduced the humidity levels in the system, mitigating moisture-related damage to equipment.
3. Improved Energy Efficiency and Extended Equipment Life: By providing a buffer, the receiver tanks reduced the frequency of compressor start-stop cycles, thereby lowering energy consumption and decreasing wear and tear on the compressor, extending its lifespan.

Results and Benefits:

• Significant Reduction in Breakdowns: The previous daily average of up to 20 air-related breakdowns was reduced to zero after the overhaul.
• Increased Production Efficiency: The maintenance team was no longer constantly battling breakdowns, allowing operators to focus on production targets. This led to improved throughput, reduced scrap rates, and increased productive hours.
• Enhanced Product Quality: More filter components passed integrity tests, assembly precision improved, and online adjustments were reduced.
• Cost Savings: The project not only brought operational success but also significant economic benefits. Mann+Hummel saved approximately $500,000 through compressor rentals during the transition period and received a $300,000 rebate from Duke Energy.

This case study effectively demonstrates:

• The decisive impact of correctly sizing and installing air receiver tanks on overall compressed air system performance.
• That receiver tanks are more than just simple storage vessels; they are key components for pressure stabilization, moisture management, and energy efficiency optimization.
• That investing in appropriate air receiver tanks can significantly boost productivity, lower operating costs, and enhance system reliability.