Empowering the smart factories by achieving efficiency and sustainability with advanced technologies

By Staff Report January 13, 2025 6:38 pm IST

All the minor aspects, including your compressor systems, are equally crucial in building a smart factory. Chicago Pneumatics is deploying the latest technologies to help manufacturers develop smart factories cost-effectively with its new solution, Airchitect.

Asmart factory has the highest power efficiency for optimum usage of smart technology. It is a digitised manufacturing facility that uses connected devices, machinery, and production systems to collect and share data. The data is used to improve processes and address issues.

The ultimate aim of a smart factory is to become completely independent – that is, able to use the right data to pinpoint and fix malfunctions or streamline processes without the need to pause production. This connected environment enables the improvement of processes through automation and selfoptimisation.

Chicago Pneumatics strive to achieve the goal of reducing its carbon footprint and boosting production efficiency by providing smart technologies like-

• Permanent magnet Technology
• VFD compressors
• E-control
• Icons
• Airchitect

These solutions help customers build smart factories, optimising their full potential and meeting their requirements with precision. By integrating smart technologies, customers save energy and maximise the efficiency of their compressors.

IPM or VFD technology

Energy efficiency is a crucial factor in compressor systems, with energy costs making up the majority of their total cost of ownership. These compressors utilise advanced technologies for customers with variable compressed air demands to optimise performance and reduce costs. The IE4 Super Premium Efficiency iPM motor delivers superior energy savings compared to traditional induction motors, while the direct-drive configuration enhances efficiency and reliability. Its proven oil-cooled design ensures consistent operation even in demanding conditions, and a horizontal layout simplifies maintenance. This system exemplifies innovation, durability, and value with the latest IP protection class and a fully in-house design.

Similarly, VFD technology enhances energy efficiency through its variable speed functionality, correlating energy consumption with demand. These compressors intelligently adjust air supply to match requirements, eliminating wasteful unload cycles. The soft start-up feature prevents sudden power surges, stabilising energy usage and increasing system reliability.

IPM and VFD technologies reduce energy expenses while replacing outdated systems with smarter alternatives. This integration empowers businesses to improve efficiency, lower costs, and adopt sustainable industrial practices for a better future.

Smart connectivity

Technological advancements in IoT and automation have reshaped Chicago Pneumatic systems, enhancing control, monitoring, and efficiency. With ICONS, users gain real-time monitoring and analytics to oversee critical compressor data, including air pressure and energy use, optimising maintenance schedules and minimising downtime. ICONS cloud-based platform allows for predictive maintenance, automatically flagging potential issues before they lead to costly disruptions, thereby aligning well with Industry 4.0 standards.

The EControl system further enhances operational flexibility by enabling centralised control over multiple compressors. This system adjusts compressor outputs based on real-time demand, ensuring energy efficiency while maintaining optimal air pressure across various applications. Together, ICONS and EControl offer robust data visibility, streamlined energy management, and reduced operational costs, all while supporting a connected manufacturing environment. These technologies showcase Chicago Pneumatics’ dedication to providing high-performance and sustainable solutions.

Know your power consumption

Smart people use advanced technologies and measure their use to improve productivity. To do so Chicago Pneumatic Compressors propose a solution named “Airchitect”. With air audit using the tool, calculate your savings.

How? It’s important to understand that compressors can experience energy losses of up to double-digit percentages due to unloading, and every unit increase in pressure adds 7% to estimated power consumption. Leaks in the pipelines further contribute to unnecessary energy costs.