Compressor Installation at North American Beverage Company

BACKGROUND

A North American beverage and coffee-making company operating in both the beverage and appliance manufacturing industries, engaged New England’s premier provider of intelligent buildings & energy solutions, Compressor Energy Services (CES), A Fidelity Company — an Energy Solutions Division of Environmental Systems Company, A Fidelity Company — to support a critical mechanical infrastructure upgrade at its Aspers, Pennsylvania production facility.

With several compressed air units approaching end-of-life, the site was experiencing reliability challenges, system inefficiencies, and deteriorating air quality, all of which posed risks to production uptime. The company sought a modern, energy-efficient solution that would not only replace aging equipment but also support its long-term operational strategy and sustainability goals. CES was selected to design and implement the upgrade, leveraging its compressed-air expertise and its collaboration with fellow Fidelity Building Services Group companies: Fidelity Mechanical Services, which handled the installation, and ServiceX MEP, A Fidelity Company, which handled the electrical components of the project.

OBJECTIVE

The facility relies heavily on compressed air across its operations, from packaging machinery to general food processing. The primary objective of this project was to replace outdated compressed air equipment and address system inefficiencies, including inadequate piping and inconsistent air quality.

The compressed air infrastructure at the facility consisted of three systems: a low-pressure oil-free system, a low-pressure oil-flooded system, and a high-pressure oil-free system serving the blow mold operation. Most low-pressure compressors were more than 20 years old, and the oil-free system lacked redundancy, relying on the high-pressure system as backup. Upcoming expansions, including two new Tetrapack Speed lines, were expected to further strain these systems.

Air quality and treatment were major concerns. Several compressors lacked functioning dryers, sending wet or oily air into the system. Refrigerated dryers in the oil-free system were inconsistent, creating potential reliability and maintenance challenges. Additionally, system pressure fluctuated widely, and aging or compromised piping—some plastic with visible cracks—introduced air leaks that reduced efficiency and system stability.

The facility also relied on cross-over connections between low- and high-pressure systems for redundancy, a practice that can mask inefficiencies and place extra strain on older equipment. Overall, the compressed air system faced multiple operational challenges.

SOLUTION

CES performed metering and assessment of six existing satellite systems within the facility to identify issues. Phase 1 of the project included installing CES’s AirAnalytics® “Metering System in a Box” assessment, which provided nearly a year’s worth of data logging of equipment that was then uploaded to a website with portal access for viewing. CES then developed a comprehensive installation plan with Fidelity Mechanical Services.

Working closely with Atlas Copco, CES selected and integrated an advanced, energy-efficient compressor solution tailored to the facility’s load profile and air quality standards. Installation was executed by Fidelity Mechanical Services, with ServiceX MEP providing all necessary electrical work to tie the new system into the main power supply. Fidelity Mechanical Services also coordinated upgrades to the facility’s heat recovery duct system, which features two dampers: one vents waste heat outside during summer, while the other diverts heat back into the building during winter, providing nearly free heating. This integration ensured seamless coordination between design intent, energy recovery measures, and field implementation.

OVERCOMING OBSTACLES

Maintaining uninterrupted system operation was the project’s most significant challenge, requiring careful coordination around scheduled shutdowns and close collaboration with the client whenever CES and Fidelity Mechanical Services had to connect to existing operating airlines. CES engineered a detailed sequencing plan that allowed for safe transitions between equipment without impacting production.

The project also demanded strict adherence to food safety and regulatory requirements. All work needed to meet food-grade standards, PPE protocols had to be observed, and numerous safety policies were enforced throughout the installation. The ability of the team to execute the project flawlessly under these conditions — without any interruptions or safety incidents — reflects Fidelity’s expertise and attention to detail, leaving the client fully satisfied with the outcome.

EQUIPMENT DETAILS

The project included the installation of an Atlas Copco ZT160VSD+FF, a 215 HP, air-cooled, oil-free, variable frequency drive (VFD) compressor featuring integrated heat-of-compression drying. This high-efficiency system improved air quality, reduced energy consumption, and supported long-term reliability and sustainability goals.

In addition, TruLink Applied System Technologies (AST) piping was installed. This high-quality aluminum piping combines the durability of marine-grade aluminum with innovative, easy-to-install technology. The client was impressed not only with the clean aesthetics of the piping but also with the overall installation, ease of use, and long-term reliability it provides.

RESULTS

Before installation, CES performed system metering and analysis to establish a baseline load profile and identify opportunities for improvement. After commissioning, the upgraded system is estimated to deliver $68,000 in annual electrical savings, driven by improved compressor efficiency and optimized system performance.

The team also implemented a heat-recovery solution within the warehouse, repurposing the compressor’s waste heat to reduce energy usage further, with additional measurable savings to be calculated.

The collaboration among three Fidelity companies — CES, Fidelity Mechanical Services, and ServiceX MEP — kept the entire project in-house, executing design, installation, and electrical integration without relying on outside contractors. This project is a testament to Fidelity’s expertise, coordination, and ability to deliver complex, multi-faceted projects under one umbrella.

OPERATING COMPANIES

• Compressor Energy Services, A Fidelity Company
  • Compressed Air
  • Energy Optimization Solutions
• Fidelity Mechanical Services
  • HVAC/Mechanical
  • Heat Recovery Duct
  • Piping
• ServiceX MEP, A Fidelity Company
  • Electrical

PARTNERS

• Atlas Copco
  • Air Compressor Vendor

CLIENT

Large North American Beverage Company

INDUSTRY

Food Manufacturing

CATEGORY

Compressed Air Equipment Replacement, HVAC/Mechanical, Heat Recovery Ductwork, Piping, Electrical

BUILDING TYPE

Factory

GROSS SQUARE FOOTAGE

600,000 SF

START DATE

December, 2024

END DATE

November, 2024