The CNC machining industry is growing rapidly. A relatively automated, precise process means machines can cut with accuracy and craft thousands of pieces. Machines like this utilize compressed air in many ways. One CNC machining company takes advantage of energy incentives and variable frequency technology to increase their capacity and savings at the same time.

Company Background

GrovTec Machining is a family-owned CNC machining company based in Wood Village, OR. The company machines parts & components for industries such as aerospace, military & defense, electronics, firearms, and more. Since 2006, GrovTec has been using their expertise to create precision screw machine products. Parts are made with everything from steel to plastic, and their expansive facility can churn out hundreds of thousands of pieces per day.

GrovTec’s Multi-Spindle Screw Machining Facility serves industries from medical to aerospace.

Compressed Air: A Critical Resource

To understand how GrovTec utilizes compressed air, first let’s dive into the basics of CNC machining:

CNC stands for Computer Numerical Control. Pre-programmed computer software controls the movement of the tools and machinery to create a product out of blank stock. The machines use a 2D or 3D CAD drawing that has been turned into computer code. A trial run of the machine’s new program is always run to make sure there are no mistakes before heading into production.

This process is mostly automated; operators ensure the program is running properly, inspecting, sorting & cleaning the pieces as they are released from the machine. At GrovTec Machining, compressed air is used to clean contaminates from the machine & parts and to run certain pneumatic machines. That means they’re using compressed air all day, every day.

“I tell everybody our compressors, the heart of the company, if that compressor's not working, nobody's working that day besides a few machines that don't require air,” the shop floor manager noted.

Compressed air lines lead to nearly every piece of equipment at GrovTec.

Increasing Capacity

GrovTec has worked with Rogers since their inception in 2006. When it was time to create additional compressed air capacity, they turned to Rogers once again. Their current unit, a KV Series, is a workhorse for their main production facility. But they’re growing fast, and needed more space (and more compressed air).

In another building, a brand new operation is taking shape. With more space means more compressed air needed to fuel operations. Their newest building features a KIV-40-100 oil-lubricated compressor, Zeks 200HSG Cycling Refrigerated Dryer, and Parker Coalescing Filter to meet Clean, Dry Air (CDA) requirement, all of which are distributed and sold through Rogers.

Compressed Air Purity

When building a compressed air system, one of the first questions asked is “what quality of air does your facility require?” Industries such as medical, food & beverage, and semiconductor require Class 0 air. According to ISO 8573-1 requirements, this means that no oil or contaminants may enter the system at any point. It is referred to as CDA (clean dry air).

GrovTec, being a machining company, does not need to meet such stringent air quality requirements. However, removing liquid and condensation from the air keeps the plant running smoothly and protects the product. Liquid running through the piping system can cause costly leaks, blockages, and potential failures.

Coalescing filters are placed before the dryer, removing condensation from the air and making the dryer’s work easier. Adding this filter to their system ensures that the air leaving the compressed air system is free from water, aerosols, lubricant & oil.

RELATED: WHAT IS A COMPRESSED AIR SYSTEM?

Variable Speed Drive Technology

Both compressors that GrovTec Machining operates are VFD compressors. Variable Frequency Drive (VFD) technology allows the compressor to increase and decrease load as the facility requires. Fixed-speed compressors run at one speed all day, regardless of demand.

GrovTec’s sizable factory floor is not always running at full capacity. With different shifts & order volume, the machining floor utilizes different machines for certain jobs. By using VFD technology, the company saves in energy costs, as the compressors can match air output with air use.

Reaping the Reward of Energy Incentives

Energy is at a premium, and will always be. Many companies are looking for ways to save when it comes to energy costs, which is critical when 80% of the cost of owning a compressor is energy. Upgrading equipment and adding new equipment that is more energy-efficient can help facilities save thousands in energy savings.

Many companies use energy incentives to facilitate capital expense. When Rogers mentioned these incentive programs, GrovTec took advantage to purchase the compressed air system required for their new building. Rogers facilitated the implementation of the incentive and helped GrovTec with proper documentation. With the incentive in place, the CNC machining company can expect to have their new compressed air system paid off in just over 4.5 years.

RELATED: HOW TO JUSTIFY CAPITAL INVESTMENT FOR AIR COMPRESSOR AND VACUUM PUMP SYSTEMS

Precision Machining Meets Premier Service

At Rogers, we pride ourselves on providing quick, quality service 24 hours a day. Our technicians also provide factory service maintenance every thousand hours. Think of it like getting an oil change in your car; air compressors need regular maintenance too. Our fleet of local technicians takes care of the maintenance so you don’t have to.

“We're set on [service] every thousand hours for the 100 horse [compressor]”

GrovTec relies on our technicians to diagnose and solve any problems that occurred with their compressed air system. When the facility’s main 100hp compressor was squealing, the maintenance manager immediately made a call to his service contact at Rogers.

“I think the main piston was kind of stuck in a position that didn't allow air to come in, so it was just kind of drawing air. So the tech came out the same day and took care of it for us. “

Similarly, when their refrigerated dryer went out, Rogers technicians were just a call away.

“Every time we have something wrong with it, I make a phone call that same day or the next day service comes out and takes care of it. So we're never really down, so real reliable.”

GrovTec is still growing, building their new assembly and plating facility. With so many CNC machines working to produce hundreds of thousands of components with precision, they can rest easy knowing that their compressed air provider will always be ready with efficient service, and product solutions for their entire system end-to-end.