Healthy Paws
- Reduced energy costs through intelligent staging
- Increased confidence to scale operations
About The Company
Our client is a Canadian manufacturer of premium raw pet food, operating from a purpose-built facility in Ontario’s Niagara Peninsula. Their locally sourced chews, treats, and probiotic blends are distributed nationwide. As a growing company, our client prioritizes uninterrupted production and high product quality.
The Challenge
Since 2020, the company had relied on a pre-owned Kaeser AirCentre SM7.5. The compressor had proven to be reliable, efficient, and cost-effective. But as the business scaled and more production equipment was introduced, air demand began to exceed capacity.
During peak operation, the SM7.5 struggled to maintain pressure, triggering low-pressure alarms that caused sensitive production machinery to shut down. These unplanned stoppages reduced output, jeopardized delivery timelines, and increased operational stress.
The technical team was committed to sticking with Kaeser equipment and valued their ongoing relationship with Air Solutions Canada. But they were unsure whether to replace the existing unit or add a second compressor to meet rising demand.
Engagement Details
Belt Drive Compressor Specialist Quinton Gregor visited the site to assess performance and gather data. Using the SD card functionality in the Kaeser Sigma II controller, Quinton recorded real-time information on flow (CFM), pressure (PSIG), and power usage (kW).
That data was reviewed by Kaeser’s engineering team in Montreal, who conducted a full Kaeser Energy System Study (KESS). The analysis confirmed that demand had grown by 15%—not enough to warrant replacing the original compressor, but enough to require additional capacity.
Other considerations included:
- Limited electrical service at the facility
- Constrained floor space in the compressor room
- No backup compressor in place
Ongoing Maintenance
To protect performance and extend equipment lifespan, the company enrolled in a quarterly preventative maintenance program. Our service team now provides routine inspections and service for:
- Both compressors
- Integrated refrigerated dryer
- Automatic condensate drains
- Inline oil-removal filters
- Kaeser Aquamat condensate management system
The Solution
We recommended installing a second Kaeser compressor, configured to operate in a smart lead/lag arrangement using the Sigma II control system.
The new unit was installed as the lead compressor, with the SM7.5 designated as the lag unit. This setup provided immediate benefits:
- The lag unit only starts when needed
- System pressure is stabilized
- Energy is saved during low-demand periods
The lag compressor idles for four minutes before shutting off if no further air is required. This setup supports energy efficiency and system responsiveness. While the Sigma II controller allows users to alternate the lead/lag status, the company opted to prioritize the new compressor as the lead to take full advantage of its five-year warranty.
Results
The manufacturing facility now operates with a smart, responsive compressed air system that adjusts in real-time to production demand. The new setup delivers consistent air pressure during high-output periods, without wasting energy or requiring manual intervention.
Outcomes include:
- Stable air supply under full production loads
- Elimination of low-pressure shutdowns
- Reduced energy costs through intelligent staging
- Increased confidence to scale operations
- Ongoing system health through regular maintenance
For a company focused on product quality and consistent supply, investing in a smarter air system was a critical move—one that’s now paying off in uptime, reliability, and readiness for growth.
About Air Solutions Canada
Air Solutions Canada is a compressed air specialist serving manufacturing clients across Southern Ontario. With the region’s largest service team, over $2 million in inventory, and a 90% first-time fix rate, we deliver solutions that work—fast. From consultation and installation to maintenance and emergency support, we design systems that meet real-world production needs with maximum reliability and efficiency.
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If you’re expanding and your compressed air system is falling behind, we can help. Let’s build a solution that grows with your business.