One of the conditions written into a service level agreement with a world leading manufacturer is for John Morfield Ltd to investigate on-going cost savings. One such area for savings was identified in the HVAC systems which provide the factory production area with a clean environment. Nine air handling units with capacities from 15000 m3/hr to 32000 m3/hr were fitted with panel filters followed by 8 pocket glass filter bags which were ensuring the specified volume and cleanliness of air required at a cost which was accepted as being reasonable to the customer.
The units were regularly monitored by the customer and magnahelic gauges fitted to ensure filter life was maximized as opposed to time based change-outs where filters may be change prematurely. John Morfield engineers recommended that a move to rigid bags with a mini pleat construction could bring significant savings due to the larger surface area leading to significantly lower initial resistance and extended service life. A trial was considered unnecessary as the technical proposal was accepted by the customer and the rigid bag filters were fitted.
The customer monitored the condition of the filters and air quality for 12 months which resulted in the rigid filters achieving double the service life of the original filters with a subsequent saving over £27,000 in filter spend alone in the first year with the savings being repeated year on year. Nylon fibres producer benefits from improved air filter technology. Further savings were also acknowledged by the customer due to less filters for disposal and man-power savings not included within the above figures.