Saving Energy and Operation Costs

The Client

Midland Plastics is one of the Midwest’s oldest and largest plastics suppliers with its headquarters in New Berlin, Wisconsin. They produce high-quality, custom plastic component parts utilizing advanced routing, machining, and milling technologies.

Whether the needs are dispensing head for food/beverage, a livestock/poultry feeder bin, or everything in between, Midland Plastics has a plastic solution that is lighter, more resistant, and longer lasting than traditionally used materials.

Midland’s in-house Engineering/Design capabilities, combined with complete manufacturing technologies, ensure they can bring to life any plastic need. Learn more about their capabilities, experience, and locations at https://midlandplastics.com/.

The Challenge

Midland’s existing vacuum pumps (Quincy QSVI-40 and (2) 40HP competitor fixed speed machines operating at 24”HgV) were being serviced by one of Quincy’s distributor’s, Zorn Compressor and Equipment. When the distributor asked how much vacuum they use, the customer replied “I don’t really know for sure. I think a second pump comes on sometimes”. That prompted the idea of conducting a vacuum audit to get an accurate assessment of what the process truly required.

Audit Results – The audit measured the vacuum level and motor amps over time. It was determined that their application required 553 ACFM @ 24”HgV, and was consuming approximately 44.25 HP to meet that demand.

The Solution

An evaluation of variable speed curves showed that a QSV 1100 E could meet the demand and consume approximately 17.5 HP less than the existing installation. Based on the customer’s cost of electricity and the annual operating hours, the solution represented a savings of nearly $9K in operating costs alone. For this end-customer, reducing the overall vacuum footprint was also of strong interest. Prior to the audit, a two pump solution (to provide redundancy) using larger pumps was presumed necessary. Excited to save energy and floorspace, the customer ordered the (2) QSV 1100E pumps AND an ECOntrol 3.0 (a multi-pump controller) to ensure the pumps are efficiently optimized as a central system!

With excellent coordination between Zorn Compressor and Equipment’s sales and service teams, the installation and commissioning yielded a beautiful, clean, and effective installation.

Key Takeaways

Auditing an existing installation is an extremely effective way to remove ambiguity, confirm/dispel preconceived notions of solutions, quantify savings, and provide clients with exactly what they need! If you suspect your vacuum system is underperforming, or curious to know if there’s a more efficient solution, Contact the Quincy Vacuum team today! Let the data guide the way!

Download Saving Energy and Operation Costs Case Study

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