When a 200-hp compressor failed at Aspen Products' paper packaging plant, the immediate concern wasn't efficiency, but rather to keep the presses running. Nearly a year later, the fallout from that failure has turned into a measurable energy win.

Aspen's approximately 600,000-sq-ft (55,742-sq-m) facility runs compressed air across printing presses, converting machinery, packaging lines, conveyors, and robotic handling systems. When the plant's aging compressor lost its motor, maintenance supervisor Mike Gilvin called G3 Industrial Solutions for emergency rental air.

G3 delivered a 100-hp ELGi EG75-125 rental unit in about two and a half hours and had it wired into the plant's air system within roughly four hours of the initial call.

"We were in a down condition and needed air quickly," Gilvin said. "Luke had the rental unit here within a couple of hours, and we had it connected and running within about four hours of making the call. That response helped us keep production moving."

Aspen ran on the rental unit for about two and a half weeks while the original compressor was repaired. Satisfied with its performance, the company bought the EG75-125 outright and kept it in permanent service.

From Emergency Fix to Energy Strategy

Months later, a second aging 200-hp compressor failed. Rather than treat it as another one-off repair, Aspen and G3 used the moment to rethink the plant's air supply. G3 recommended an ELGi EG160V-125 variable-speed compressor, which adjusts motor speed to match Aspen's fluctuating printing, converting, and packaging demand instead of running at a fixed output.

The unit arrived within days and was online in about a week.

Running the fixed-speed and variable-speed compressors together, Aspen is now tracking roughly 12% lower energy consumption than its old equipment, while holding system pressure more consistently across the two-building facility. The company monitors electrical usage through panels throughout the plant to track the improvement.

"They make a lot of air for the amount of power they use," Gilvin said. "They run cooler, they've been reliable, and we haven't had any issues with either unit."

Because compressed air contacts product at several points in Aspen's process—the company undergoes an annual three-day food-contact certification audit—downstream filtration maintains required air quality.

Built for Uptime

G3 now provides quarterly preventive maintenance on both units, including oil sampling, filtration service, and routine inspections. The distributor also stocks common compressor sizes, including 100- and 200-hp units, in its rental and new-equipment inventory specifically to respond to unplanned failures.

"We try to keep common sizes such as 100- and 200-hp compressors available because response time matters when a customer is down," said Luke Johnson, vice president and co-owner of G3 Industrial Solutions. "That gives us the ability to provide rental air immediately, support the customer through an emergency, and then help determine the right long-term solution."

Aspen has had no operational issues with either compressor and plans to consider ELGi and G3 again as other aging units in the facility are near replacement.