EMC Upgrade with Containerised StationPack SE Compressor Stations at a Casting Plant

The client is a casting plant belonging to a major vehicle and logistics-equipment group. As part of a group-wide ESG programme, it aimed to cut energy use by 25–30% using energy management contracts (EMC), under which an energy-services partner funds the upgrade and is repaid from the savings.

The plant’s compressed air came from three old compressors with a combined rated power of 594 kW. They were inefficient, needed considerable maintenance and labour, and the supporting dryers and controls were outdated. The upgrade had to cut energy use and operating cost without disrupting casting production.

Based on the plant’s actual operating conditions, the three old machines were replaced by three integrated, containerised SIND StationPack SE series air compressor stations with a combined rated power of 480 kW. Each container houses:

• a high-efficiency compressor;
• an air-cooling system;
• a refrigerated air dryer;
• an intelligent control system.

The stations arrive as complete, pre-assembled units. This shortens installation and commissioning on site and keeps the compressor room footprint small. The project was financed under the EMC model, so the plant did not need to make an upfront investment.

After installation, commissioning and operational verification, the project met its overall targets:

• Installed power reduced from 594 kW to 480 kW.
• Electricity consumption down about 19% while maximum air output rose about 19% in initial operation.

Containerised, plug-and-play compressor stations offered the plant a fast, low-disruption way to modernise its air supply under a no-capex contract.