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Collective Arts Brewing

Collective Arts Brewing

Collective Arts Brewing is a craft brewery in Hamilton, Ontario, Canada, founded by Matt Johnston and Bob Russell. It is a grassroots brewery whose mandate is to combine "the craft of brewing with the inspired talents of emerging and seasoned artists, musicians, photographers and filmmakers."


Unnecessary run time, aging equipment, & excessive heat

Since their inception in 2014, Collective Arts had been using a 75hp air-cooled Kaeser CSD75 compressor that they inherited from the previous tenant. They approached Air Solutions Canada for service and advice. During a free discovery call, Air Solutions Canada identified several opportunities for improvement with the existing compressed air installation:

Demand-side investigation, leak detection, & air demand analysis

We began with a demand-side investigation and leak detection study to fully understand how the system was currently using air and whether there were any obvious efficiency and repair opportunities. The leak detection study discovered 11 cfm of leaks (15% of their average air demand of 75 cfm). Most leaks were joints or fittings that could be easily repaired by their pipefitter.

We next conducted an Air Demand Analysis. This continuous study measures the compressed air generation, consumption, pressure and electricity usage every four minutes to determine the actual compressed air performance over a representative work week. The results were as follows:

Two compressors are better than one

Kaeser’s engineer concluded that an 18-month ROI could be achieved with new equipment, heating, and cooling solutions for summer and winter months, and 5-year Kaeser “bumper-to-bumper” warranty coverage.

Typically, a single variable-speed compressor is the recommended solution for a plant with this kind of erratic demand and consumption profile; however, Kaeser engineers demonstrated that this was not the most efficient or cost effective solution for this case. Instead they recommended two 30hp fixed-speed compressors.

New Installation 5 Resize

Kaeser’s KESS study, (Kaeser Energy System Study), predicted a specific energy consumption of only 22.12 kW/100cfm based on the brewery’s air consumption profile. In addition to energy savings, having two compressors also ensures that pneumatic energy is available when one compressor needs service. In addition, fixed-speed compressors have a significantly lower capital cost than variable-speed drive compressors to begin with, and have fewer moving parts. Fixed-speed machines can also better tolerate brown outs and dirty power.

The KESS report also confirmed that adding air storage would help to sustain constant system pressure and reduce the load/idle demands on the air compressor.

The existing 400-gallon air receiver was deemed to be undersized, based on “best practice” storage recommendations (3 to 6 gallons per total cfm output of the compressors). To address this, an additional 660 gallons of air storage was added to the existing 400 gallons. With the 1060 gallons of storage in place, the new ratio was 3.75 gal to 1 cfm.

Finally, we recommended and executed the design and installation of fresh air intake and heat recovery ductwork. The ductwork is designed to eject heat from the compressor room during summer months and direct the hot air discharge into the building for space heating in winter. With this added control, the efficiency of the compressed air system was greatly improved. Controlling the air temperature in the compressor room helps the system deliver dry compressed air to the facility in a reliable manner, while extending the service life of the compressed air equipment. More importantly, heat recovery savings were improved by virtue of the air compressor hot air discharge being directed into the warehouse. The increased ambient temperature in this area means that natural gas heating was subsequently reduced.

ROI achieved in just 18 months

The total cost of the equipment installed for this project will be recovered in less than 18 months, when one considers efficiency and maintenance savings associated with the new equipment. In addition to replacing equipment that was nearing the end of its useful life, the customer now has some redundancy in their compressed air system. With two independent compressors, each with integrated refrigerated air dryers, the facility will have enough compressed air to operate most of their production, even if one of the compressors is down for service or maintenance.

“We couldn’t be happier with the level of expertise and service provided by Air Solutions Canada and Kaeser throughout this project. The resulting cost savings and performance are great, and the built-in redundancy gives us peace of mind.”

David Muldoon
Engineering Manager & Process Specialist
Collective Arts Brewing

Collective Arts 1

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Contact Air Solutions Canada to arrange your own comprehensive Air Demand Analysis, or a complimentary leak detection demonstration.

Just give us a call at 289-902-3576 or use the form above to get in touch.

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The ultimate guide on rightsizing your compressed air system

Choosing the right compressed air system is crucial to minimize the total cost of ownership. How do you calculate the air demand in flow rate (CFM) and pressure (PSIG), what's the power requirement (V), and how does that translate in a compressed air system with one or more compressors (hp)?

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When you speak to us, ask for an Air Demand Analysis. It will give you the performance data of your current compressed air system and show the savings you can generate. We offer a performance guarantee - if we don’t identify inefficiencies within your system which are equivalent to the cost of the ADA study, then the study will be free! And in the meantime, download the Ultimate Guide on Rightsizing your Compressed Air System. You can stop being frustrated that they were over promised and under delivered, and instead be confident with a radically different solution that serves your needs better at a lower cost. 


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