Overview
Client: Plastic resin manufacturer
Location: Norfolk
Industry: Plastics and polymer manufacturing
Solution: 22kW Variable Speed Drive air compressor with intelligent compressor management system
A leading plastic resin manufacturer in Norfolk strengthened its long-standing partnership with Avelair by investing in a third air compressor. Following detailed data logging and system analysis, the company upgraded its compressed air system to improve efficiency, reduce energy costs and enhance operational resilience.
The challenge
The manufacturer had been operating two 15kW fixed speed Avelair air compressors for over ten years. While reliable, the system presented opportunities for improvement:
- Rising energy costs
- Fluctuating air demand
- Limited optimisation between compressors
- No clear visibility of potential energy savings
With compressed air playing a critical role in resin production, the business required a solution that would deliver measurable efficiency gains without compromising reliability.
The solution – Data-led upgrade to variable speed drive technology
Avelair carried out comprehensive data logging across the site’s compressed air system. The results highlighted potential energy savings of approximately £2,000 per year through the introduction of a Variable Speed Drive (VSD) compressor.
The recommended solution included:
- 22kW VSD rotary screw air compressor – Installed as the lead compressor
- Integrated inverter drive – Adjusts motor speed in line with real-time air demand
- SX compressor management controller – Intelligently coordinates fixed and variable speed compressors for optimum efficiency
The VSD compressor now automatically ramps motor speed up or down to match demand, significantly reducing unnecessary energy consumption and lowering the site’s carbon footprint.
The results
Measurable energy savings
Data-led specification ensured the projected £2,000 annual energy saving could be achieved through improved system control and reduced off-load running.
Optimised system performance
The SX management controller ensures the fixed and variable speed compressors operate in the most efficient sequence, maximising overall system performance.
Reduced carbon footprint
Lower electricity consumption directly contributes to improved environmental performance.
Improved resilience
With three compressors on site, the Norfolk manufacturer now benefits from built-in backup capacity during servicing or maintenance periods.
The value of compressed air data logging
This project highlights the importance of monitoring compressed air systems. Avelair’s air compressor data logging service provides clear insight into:
- Actual air demand and usage patterns
- Leakage rates within pipework systems
- Opportunities to reduce running pressure
- Potential efficiency improvements and cost savings
By analysing real performance data, businesses across Norfolk and East Anglia can make informed investment decisions that deliver rapid return on investment.
Looking for air compressors in Norfolk?
If your manufacturing business is operating ageing or inefficient equipment, Avelair can provide expert data logging, consultancy and installation of energy-efficient air compressors in Norfolk and across East Anglia.
Contact our team on 01359 272828 to arrange a compressed air assessment and discover how much your system could save.
Posted on:
February 25th 2026