Report Spring 2019 - Kaeser Compressors

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Report Spring 2019 - Kaeser Compressors
report   Spring 2019
Report Spring 2019 - Kaeser Compressors
Contents                           Issue Spring 2019                                                                                                                                                                                                                                       Editorial

                                                                                  3         Editorial

                                                                                  4         KAESER KOMPRESSOREN Turns 100!
                                                                                            From a machine workshop to a global leader

                                                                                  8         ‘Integrated Industry – Industrial Intelligence’                         100 Years
                                                                                            Hanover Fair 2019 – Hall 26 Booth C51
                                                               4-7
                                                                                                                                                                    KAESER KOMPRESSOREN
                                                                                  10        Flying High with Clean Air
                                                                                            FACC – an Austrian global player                                        100 years ago, my grandfather, Carl Kaeser Sr. – together with
                                                                                                                                                                    eight employees and two apprentices – founded a machine
                                                                                  13        Variable Pressures and Heavy Duty Site Performance                      workshop that specialized in gear cutting and car engine over-       Dipl.-Wirtsch.-Ing.          Dipl.-Wirtsch.-Ing.
                                                                                            New MOBILAIR M171 portable compressor                                                                                                        Thomas Kaeser                Tina-Maria Vlantoussi-Kaeser
                                                                                                                                                                    hauling. In 1947, my father, Carl Kaeser Jr., made the decision      Chairman,                    Managing Board

                                                                                  14        Spice is the Variety of Life!                                           to start manufacturing the first serial production reciprocating     Managing Board

                                                                                            The Fuchs Group – cultivating a world of good taste                     compressors.
                                                               8-9                17        In the Service of Research                                              Today, KAESER KOMPRESSOREN SE remains a fully                        The solutions we seek will be found only through collaborati-
                                                                                            Compressed air for the Institute of Thermal Turbomachinery at the KIT   family-owned business that offers and markets its industrial         on: with the development of the potential harbored in human
                                                                                                                                                                    compressed air technology products and services in over 100          communities that comes to fruition only through open and
                                                                                  20        The Beauty of Water
                                                                                            SIGMA AIR UTILITY at Neoperl GmbH in Müllheim                           countries through its own subsidiaries and exclusive sales part-     constructive co-operation between dedicated people who
                                                                                                                                                                    ners. KAESER KOMPRESSOREN has remained competitive                   are free to act on their own initiative.
                                                                                  23        The Sky’s the Limit                                                     for 100 years and has been able to grow successfully through
                                                                                            Premium quality craftsmanship in series production:                     its combination of uncompromising customer orientation and           Digitalization, the Internet of Things (IOT), Smart Factory,
                                                                                            AutoGyro GmbH, Hildesheim                                               constant innovation with highly motivated and expertly skilled       networking and artificial intelligence are all helpful tools to
                                                           28-29
                                                                                                                                                                    employees and sales partners.                                        make companies more efficient, flexible and innovative, and,
                                                                                  26        Prestige Vehicle Repair and Customization
                                                                                            Long-term customer satisfaction: Koudsy Body Works (KBW), Australia                                                                          ultimately, more competitive. This gives rise to completely
                                                                                                                                                                    We are all very grateful and can look back on our 100-year           new business models for products and services that bring
                                                                                  28        The World’s Largest Trade Fair                                          history with a sense of great pride and accomplishment.              significant measurable benefits to our customers.
                                                                                            KAESER KOMPRESSOREN at bauma 2019                                       Moreover, our history is not only a basis for the present and a
                                                                                            Booth FM.708/15 and FM.708/17                                           solid foundation to enable us to look firmly and clearly to the      Every era has its own challenges, potential and oppor-
                                                                                                                                                                    future, but is also the basis for us to meet and overcome the        tunities. The guiding principle that helped my parents and
                                                                                  30        ‘Innovating the World of Textiles’
                                                           30-31                            Compressed air for the textile industry at ITMA 2019 in Barcelona,
                                                                                                                                                                    ever-evolving challenges that the future has in store. Breath-       grandparents in their decisions in the past can therefore
                                                                                            Hall 6, Booth D101                                                      taking possibilities stand before us, which, at first, may present   also be an inspiration to us today: set clear and innovative
                                                                                                                                                                    themselves as unsolvable problems. However, we need to               customer- and employee-oriented goals, and have a burning
                                                                                                                                                                    tackle and solve these problems, but this cannot be achieved         desire to achieve them.
                                                                                                                                                                    by individual skilled people.
Imprint:
Published by: KAESER KOMPRESSOREN SE, 96450 Coburg, Germany, Carl-Kaeser-Str. 26
www.kaeser.com
Editorial office: Petra Gaudiello (resp.), Email: report@kaeser.com
Layout: Sabine Deinhart, Kristina Seeliger
Photographs: Marcel Hunger
Printed by: Schneider Printmedien GmbH, Weidhausen
The editorial office cannot accept liability for any unsolicited manuscripts and photographs.
Reproduction, including excerpts, only with written authorization.

VAT identification no.: DE 132460321
Register of companies: Coburg HRB 5382

We use and store your personal data for marketing purposes. For detailed information, see www.kaeser.com/int-en/privacy-marketing.aspx.
You can refuse the use and storage of your data for marketing purposes at any time by sending an email to: customer.data@kaeser.com.

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Report Spring 2019 - Kaeser Compressors
From a machine workshop to a global leader

KAESER KOMPRESSOREN
                                               Turns
                                                                                                       1919: the beginning                               KAESER rotary screw compressor lies              based        on
                                                                                                       Carl Kaeser Sr. establishes the compa-            the proprietary rotary screw airend with         industrial PC
                                                                                                       ny as a machine workshop on the 27th of           a new energy-saving rotor profile – the          technology, re-
                                                                                                       June, 1919 in Coburg. It was a difficult time,    SIGMA profile. Manufacturing these               duces life cycle
                                                                                                       fraught with instability, just a year after the   new rotary screw compressors begins in           costs and further
                                                                                                       end of the First World War. After starting out    1973. Over the coming years, KAESER              improves equipment
                                                                                                       as a maker of spare parts for motor vehi-         KOMPRESSOREN takes its place along-              availability. It has since
                                                                                                       cles and engines, especially gears, he later      side the world’s leading manufacturers of        become an integral
                                                                                                       branches out to produce specialized equip-        rotary screw compressors.                        part of KAESER rota-
                                                                                                       ment for the glass making industry.                                                                ry screw compressors.
                                                                                                                                                         Following the acquisition of the French          Building on the success-
                                                                                                       Through the division of Germany after the         manufacturer Compresseurs Bernard in             ful launch of the SIGMA
                                                                                                       Second World War, KAESER is cut off               1982, KAESER develops the KAESER                 CONTROL,              KAESER
                                                                                                       from a large portion of its original market in    MOBILAIR series of portable rotary screw         “computerizes” the entire
                                                                                                       the states of Thuringia and Saxony and is         compressors for the construction industry,       compressed air station in
                                                                                                       forced to pursue business in new markets in       initially manufactured in Lyon, France.          2001. With the innovative
                                                                                                       southern and western Germany. A decision          In 1991, shortly after German reunification,     SIGMA AIR MANAGER, the
                                                                                                       that was to shape the company’s future.           KAESER acquires Geraer Kompressoren-             combined benefits of a state-
                                                                                                       KAESER’s expertise in engine manufactur-          werke, one of Germany’s oldest compres-          of-the-art industrial computer
                                                                                                       ing, coupled with strong demand for com-          sor makers, and develops the OMEGA               and high-speed network tech-
                                                                                                       pression equipment in the post-war econ-          rotary lobe blower. Manufacturing starts in      nology are introduced into the
                                                                                                       omy, results in compressors being added           Gera in 1993.                                    world of compressed air tech-
                                                                                                       to the product range. The first reciprocat-                                                        nology for the first time.
Carl Kaeser Sr. established his machine workshop in 1919. Today KAESER is a highly successful global   ing compressor developed by KAESER                With SECOTEC, KAESER develops a                  This paves the way for further
                                                                                                       is shipped in 1948. Within a few years the        completely new line of energy-saving re-         gains in dependability, efficien-
supplier of compressors and compressed air systems that remains true to its roots.                     company’s reciprocating compressor pro-           frigerated dryers in 1994. In the same year,     cy and cost transparency in the
                                                                                                       gram covers the full range up to 80 hp.           Germany’s most advanced manufacturing            compressed air supply.
                                                                                                                                                         facility for refrigerated dryers goes into op-
                                                                                                       Expanding the product range                       eration in Gera.                                 The road to expansion
                                                                                                       Carl Kaeser Jr., the founder’s son, takes                                                          Various construction projects in
                                                                                                       the initiative for the company’s next stra-       KAESER launches the revolutionary                Germany and abroad create addi-
                                                                                                       tegic departure: the development of rotary        SIGMA CONTROL compressor control-                tional space over the years to meet
                                                                                                       screw compressors. At the heart of every          ler in 1998. This proprietary development,       the company’s increasing capacity

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Report Spring 2019 - Kaeser Compressors
needs. In the spring of 2002, the new man-       growth in production, KAESER expects the       the future begins to take shape at the Co-      340 energy saving dryer is selected as a fi-    KAESER creates 20 additional training po-
ufacturing center for portable compressors       new facilities to improve on-time delivery     burg site.                                      nalist for the prestigious Hermes Innovation    sitions for young people with refugee back-
(the MOBILAIR plant) opens in Coburg.            rates and boost customer satisfaction.         Another construction project is launched        Award, conferred by the Hanover Trade Fair      grounds in 2016.
In 2004, the year begins with the official       In 2008, KAESER opens a new plant for          in Coburg in September 2015. This time it       to honor outstanding and trailblazing tech-     The former youth hostel in the Ketschen-
opening of the new product development           cladding components in Sonnefeld. It be-       is for the research and innovation center –     nological developments. With its innova-        dorf district of Coburg is converted into a     eas of Europe, North America and Asia
center in Coburg, providing an ideal work-       gins manufacturing panel components,           soon to be the incubator of new ideas and       tive thermal storage system, the new dryer      residence for KAESER apprentices from all       Pacific. November 2013: With its re-incor-
ing environment for development engi-            doors and enclosures for rotary screw com-     inventions. The facility is completed in late   achieves energy savings of up to 70% com-       over the world.                                 poration as a “Societas Europaea” (SE)
neers. At the opening ceremony, Thomas           pressors.                                      2017 and the first employees start moving       pared to conventional dryers. In 2014, it is                                                    – a European stock company – KAESER
Kaeser, Chairman of the Managing Board,                                                         in.                                             selected for Plant Engineering magazine’s       In recognition of its endeavors as a provider   KOMPRESSOREN takes a further step in
says, “Our goal is to develop and deliv-         In October 2013, the company starts con-                                                       Gold Award for best product in the USA.         of in-house training opportunities, KAESER      its international strategy. The family com-
er innovative products that are tailored to      struction of a new research and develop-       Awards in Germany and                                                                           is awarded first prize in the Industry, Trade   pany is now at home all over the world, of-
customer needs in greater numbers and            ment center at the Gera manufacturing          at the international level                      KAESER as an employer                           and Services category by the jury adju-         fering uncompromising “Made in Germany”
more quickly than ever before.” In the           site. Excellence in innovation is a top pri-   Thomas Kaeser is awarded the State Medal        As one of the largest providers of ap-          dicating the “Training Ace” competition in      quality.
same year, KAESER KOMPRESSOREN                   ority. A steady stream of innovations keeps    for outstanding contributions to the Bavari-    prenticeship opportunities in its region,       December 2016. The competition is held          The managing board is comprised of the
completes construction of a state-of-the-        KAESER KOMPRESSOREN at the fore-               an economy in 2012. The ongoing devel-          KAESER KOMPRESSOREN excels in                   under the auspices of the German Federal        chairman, Thomas Kaeser Dipl. Wirtsch.-
art distribution center. Key elements of         front of compressed air drying technology      opment of innovative products, a defining       training skilled personnel. KAESER ap-          Ministry of Economics.                          Ing. and Tina-Maria Vlantoussi-Kaeser
this innovative facility, which revolutionizes   – amongst others.                              feature of the company since its earliest       prentices and trainees regularly score top                                                      Dipl.-Wirtsch.-Ing.
logistic processes throughout the company,                                                      beginnings, earns recognition and respect       results in the Chamber of Industry and          Ready for the future
include a new, fully automated high-rack         In May 2014, KAESER initiates the transi-      among the general public and industry ex-       Trade examinations, both regionally and         With over 100 subsidiaries and sales part-
warehouse and a high-performance picking         tion to a smart factory approach. With the     perts alike. In 2013, the new SECOTEC TF        nationwide. To promote real integration         ners worldwide, the international KAESER
system for small parts and spares. Apart         ground breaking ceremony for two new pro-                                                      within the company while simultaneously         group is present in all major industrialized
from laying the groundwork for continued         duction halls for rotary screw compressors,                                                    taking action to address the skills shortage,   countries, especially in the economic ar-

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Report Spring 2019 - Kaeser Compressors
SIGMA AIR MANAGER 4.0 KAESER SIGMA NETWORK
KAESER KOMPRESSOREN at the 2019 ‘Hanover Fair’ – the world’s preeminent trade
fair for industrial technology: Hall 26 Booth C51                                                                           KEY TECHNOLOGY FOR INDUSTRIE 4.0 INTEGRATED INDUSTR
                                                                                                                              KAESER SIGMA NETWORK               SIGMA AIR MANAG
Integrated Industry –                                                                                                              IOT CLIENT BIG DATA              CLOUD IOT CL    01.– 05.04.2019

                                                                                                                                                                                   We look forward to
                                                                                                                                                                                                      Hall 26
                                                                                                                                                                                                      Stand C51

Industrial Intelligence                                                                                                           PREDICTIVE MAINTENANCE SIGMA AIR MANAGER 4.0     seeing you!
                                                                                                                                                                                   Hall 26, Stand C51                       KOM
                                                                                                                                                                                                                                  PRE
                                                                                                                                                                                                                                     SSO
                                                                                                                                                                                                                                        REN

“Integrated Industry – Industrial Intelligence”: that’s the theme of this year’s ‘Hanover Fair ’, taking place on
the 1st to the 5th of April, 2019, in Hanover, Germany. The theme was chosen to embrace the far-reaching
concept of digital networking people and machines in the age of artificial intelligence.                                                                                                                                                                                             Hall 26
                                                                                                                                                                                                                                                               01.– 05.04.2019       Booth C51
“The focus is squarely on people. They          Under the motto, “Air is just the beginning,”    KAESER products and ideas will be show-         perfect combination of compressors. The                 from compressed air system maintenance          will see the new FSG with i.HOC. The pat-
make the decisions and set the tone,” ex-       ComVac, the leading international trade          cased in almost 14,000 sq. ft. of exhibition    result: unprecedented energy efficiency.                based on scheduled service intervals to         ented KAESER i.HOC rotation dryer utilizes
plained Jochen Köckler. With those words,       show for compressed air and vacuum tech-         space. For plenty of useful information and     Thanks to easy and intuitive operation,                 a predictive maintenance concept – this         100% of the compression heat. With full-
the CEO of ‘Deutsche Messe’, under-             nology, will highlight hot topics in the world   easy onsite navigation, access the ‘Han-        clear visualization and analysis functional-            greatly reduces the life cycle costs for the    flow regeneration, it reliably delivers flow
scored the role of ‘Hanover Fair’ as the        of compressed air and vacuum technology,         nover Messe’ app on your phone (available       ity, users have a full overview at all times            compressed air supply.                          rates of up to 1766 cfm and low pressure
home of industrial technology trailblazers,     including: energy and resource manage-           on the ‘Hanover Fair’ website).                 – from any PC. Combined with SIGMA                                                                      dew points at ambient temperatures of up
synonymous with progress for over seven         ment, the accelerating trend in contracting                                                      AIR MANAGER 4.0, the KAESER SIGMA                       Maximum energy efficiency                       to 113 °F – with no need for electric heating
decades. More often than not, the ideas         and operator models as all-round solutions,      To achieve truly seamless integration           NETWORK offers a perfectly coordinat-                   To learn how to achieve maximum cost ef-        or additional cooling of the regeneration air.
and trends that revolutionize industry are      and predictive maintenance in the context        of the compressed air supply into inte-         ed and secure infrastructure for intelligent            fectiveness and see the modern, high-effi-      We have further expanded our energy-
first presented to the global public in Han-    of Industrie 4.0.                                grated industry environments, KAESER            Industrie 4.0 services. Based on Eth-                   ciency rotary screw compressors that can        saving SECOTEC series, featuring the in-
over. This is where visionaries from around                                                      KOMPRESSOREN links machines using               ernet technology, the powerful SIGMA                    achieve this, visit the KAESER booth in         novative latent heat storage system, with
the world, representing diverse industrial      Key technologies for Industrie 4.0               the SIGMA NETWORK and the SIGMA                 NETWORK is a closed and secure network                  Hanover. You’ll get a close look at the in-     the addition of several new models, extend-
sectors, get together to capture synergies      When designing a compressed air sup-             AIR MANAGER 4.0 master controller. This         specifically developed to support optimal               novative water-cooled ESD rotary screw          ing the output range up to 3178 cfm for the
and to discuss and develop the solutions of     ply system as a seamlessly integrated el-        advanced controller provides optimal man-       monitoring and coordinated control of com-              compressor (flow rates: 212-1600 cfm),          first time. At the ‘Hannover Messe’ we will
the future.                                     ement in an integrated industry concept,         agement of the entire compressed air sta-       pressed air station components.                         the DSD/DSDX (141-1200 cfm) and the             be presenting the SECOTEC TG, which
                                                a key factor for success or failure is the       tion. It functions as the station’s brain and   Rounding off the KAESER Industrie 4.0                   FSD (353-2154 cfm). These systems of-           will be available on the market as of July/
The place where the future                      selection of the appropriate compressors         represents the key technology for using ser-    package is SIGMA SMART AIR. This inno-                  fer the most cost-effective performance of      August 2019. To learn more about our ser-
of industry is born                             and air treatment components. Get an up-         vices in the Industrie 4.0 world of tomorrow.   vative KAESER KOMPRESSOREN service                      any fluid-injected rotary screw compressors     vices and product portfolio, come and talk
Six leading trade fairs and one platform: at    close look at compressed air solutions that      This compressed air management system           delivers predictive maintenance combined                on the market. Also on display: the CSDX        to the KAESER KOMPRESSOREN com-
the world’s biggest industrial fair, visitors   are more than just reliable and energy-ef-       uses adaptive 3-Dadvanced Control to make       with maximum energy efficiency and com-                 SFC (flow rate: 39-618 cfm), featuring a        pressed air experts!
experience the full range of technical inno-    ficient. Thanks to advanced IT integration,      compressed air production and treatment         pressed air availability, far exceeding the             future-ready, energy-efficient synchronous
vations, starting with A for automation, and    they can also be integrated seamlessly into      smarter, more efficient and more secure         capabilities of previous systems.                       reluctance motor and speed control – in se-     We look forward to your visit and to telling
covering every key area across the entire       Industrie 4.0 production environments.           than ever before. 3-Dadvanced Control con-      This ensures real-time availability of oper-            ries production from the end of 2018.           you all about the latest technologies and
value chain.                                    KAESER looks forward to seeing you               tinually analyses all operating data, simu-     ating, service and energy data – an essen-              From the FSG series, our largest line of oil-   coming trends.
                                                at Booth C51 in Hall 26, where the latest        lates alternative actions and calculates the    tial prerequisite for making the transition             free rotary screw compressors, fair visitors
Report Spring 2019 - Kaeser Compressors
Images: FACC
               Author: Martin Gold

                        FACC, Austria’s largest aviation company, has risen to become a global player with
                    high-tech within a few decades. The high-strength lightweight components are in great
                   demand – as a result, today hardly any aircraft is delivered worldwide that does not con-
                    tain a component from the Upper Austrians. Only compressed air that is free of oil and
                                          moisture is suitable for the application of innovative technologies.

               Upper Austria, long famed as the industrial                                                                                                                                                                                                               area of expertise is the “acoustic surface.”
               heartland of the Alpine region, is now home                                                                                                                                                                                                               A robot drills hundreds of thousands of
               to a rising star in a high-growth, high-tech                                                                                                                                                                                                              approx. 1 mm-diameter holes in the inner
               sector. FACC, located just outside the town                                                                                                                                                                                                               carbon surface of an engine nacelle. The
               of Ried im Innkreis, has risen to prominence                                                                                                                                                                                                              lower end of the hole opens into a honey-
               in the aviation industry. FACC began as a                                                                                                                                                                                                                 comb-like core of expanded aluminium.

                                                                                                                Flying High with Clean Air
               spin-off from the research department of                                                                                                                                                                                                                  These holes have no effect on stability.
               Fischer, a ski manufacturer. The aviation                                                                                                                                                                                                                 However, the aluminium core has outstand-
               industry discovered the expertise in mate-                                                                                                                                                                                                                ing sound-absorbing qualities: meaning
               rial science and lightweight construction of                                                                                                                                                                                                              that the sound is damped right where it is
               the Austrian winter sports specialists back                                                                                                                                                                                                               created. A remarkable fact, instead of con-
               in the 1980s. The company’s near-meteoric                                                                                                                                                                                                                 ventional drilling methods, the holes are
               rise began with a development project for                                                                                                                                                                                                                 made by high-pressure sandblasting.
               a supporting rod on the Airbus A300 air-
               liner. The company’s list of customers now                                                                                                                            Assembling a winglet in FACC Plant 3 (Aerostructures Division).                     Environmental protection and
               reads like a who’s who of the global aero-                                                                                                                                                                                                                energy efficiency
               space industry: aircraft manufacturers such     main plant in the Alps. Today the company    Key future technology: lightweight          parts for aircraft in three main areas. Aero-    by an engine nacelle, for example – to de-                      The sandblasting process is the largest con-
               as Airbus, Boeing, Bombardier, Embraer,         employs 3,400 people worldwide, includ-      construction                                structures is the division that handles wing     termine the exact number of layers needed                       sumer of compressed air in FACC Plant 4 in
               COMAC and Sukhoi, engine makers and             ing 3,200 in Austria, who generate annual    The core competency of FACC is develop-     components such as elevators, rudders and        at every location. This results in compo-                       Reichersberg. The remainder is distributed
               their suppliers all rely on products from the   sales of approximately €750 million.         ing and manufacturing carbon composite      winglets. The Interiors division supplies air-   nents that combine the toughness needed                         across a large number of hand tools, ten-
                                                                                                                                                        craft manufacturers with passenger cabins,       for the heavy demands of aviation with the                      sioning devices on grinding machines and
                                                                                                                                                        from ceiling panels and overhead luggage         minimum achievable weight. Another ad-                          other small consumers. It is absolutely es-
                                                                                                                                                        bins to side panels. The third area – the En-    vantage of carbon: there is practically no                      sential to have a reliable and secure supply
                                                                                                                                                        gines & Nacelles division – specializes in       thermal expansion. “An aircraft taking off                      of compressed air. The KAESER experts
                                                                                                                                                        engine components and enclosures.                in a hot desert region will be exposed to                       have configured the compressed air station
                                                                                                                                                                                                         an ambient air temperature of -58 °F just                       accordingly, ensuring that fluctuating air
                                                                                                                                                        For all developers at FACC, the top design       20 minutes later,” says Christopher Jell,                       flow does not impact the economic efficien-
                                                                                                                                                        priority is to keep component weight to an       the Senior Manager of IE & FM Engines &                         cy of plant operations. Six fixed-speed rota-
                                                                                                                                                        absolute minimum. The materials of choice        Nacelles. “Our carbon components handle                         ry screw compressors of type DSD 201, 240
Images: FACC

                                                                                                                                                        for achieving that objective are carbon          these rapid and extreme temperature fluc-                       and 241 handle the baseload requirements,
                                                                                                                                                        composites. FACC produces tailor-made            tuations without the slightest difficulty”.                     while peak demand is covered by a DSD
                                                                                                                                                        lightweight components made up of hun-                                                                           281 SFC variable-speed unit. The com-
                                                                                                                                                        dreds of layers, and in some cases more          Drilling with sand                                              pressors can be switched on and off flexibly
               The engine nacelles are hardened in             Up to 1000 or more layers of carbon          FACC manufactures engine components
               the autoclave to attain their final material    composite material are combined to produce   using lightweight construction techniques
                                                                                                                                                        than a thousand. Experts precisely calcu-        FACC has gained an excellent reputation in                      to match current demand. This task is per-
               characteristics.                                engine nacelles.                             here in Reichersberg.                       late the stresses in advance – experienced       the market for its technical skills. A special                  formed by the SIGMA AIR MANAGER 4.0

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Report Spring 2019 - Kaeser Compressors
New MOBILAIR M171 portable compressor

                                                                                                                                                         Variable Pressures and Heavy
                                                                                                                                                         Duty Site Performance
                                                                                                                                                         More choices in the over 400 cfm range

                                                                                                                                                         The current climate in heavy-duty civil and       KAESER also designed the M171 with a            The high capacity, cold-start battery en-
                                                                                                                                                         commercial construction requires productiv-       new axial condensate separator installed        sure reliable operation even under extreme
                                                                                                                                                         ity and flexibility in all aspects of equipment   downstream from the compressed air af-          weather conditions. Plus, the excellent

                                                                                                                                             Top: FACC
                                                                                                                                                         selection. Power breakers, cable-blowing          tercooler to ensure even better condensate      cooling features allow the M171 to operate
                                                                                                                                                         and other air powered tools operate on var-       separation performance and reduced pres-        in temperatures up to 122 °F.
                                                                                                                                                         ious air pressures. To meet the needs of          sure losses in the system. As before, the
Maximum flexibility: the lightweight construction of the engine nacelles permits ideal streamlining of the engine in line with aerodynamic
                                                                                                                                                         this market, KAESER introduced the new            separated condensate is evaporated via the      The M171 also features an advanced en-
conditions.
                                                                                                                                                         MOBILAIR M171 portable compressors in             hot exhaust gases. Further, if the reheating    ergy-saving fan that is controlled according
                                                                                                                                                         the fall of 2018. Delivering 405 to 600 cfm       option is chosen, compressed air discharge      to operating temperature, and results in fuel
master controller with adaptive 3D pressure     8573-1 and oil purity Class 1. The result is a                                                           in variable pressures, it is a great option be-   temperature can be adjusted. All of the         savings of up to 6 percent. Users looking
control. Among other functions, it ensures      residual oil content of less than 0.01 mg/m3.                                                            tween KAESER’s award-winning M125 and             compressed air treatment methods men-           for efficiency, flexible pressure options and
that the pressure never drops below the                                                                                                                  the much larger capacities of the impres-         tioned above can be used with a microfilter     user-friendliness will find that the M171 hits
lowest permitted operating pressure                                                                                                                      sive M250.                                        combination to produce technically oil-free     the mark.
as detected at the pressure sensor                                                                                                                                                                         air.
measurement location.                      The decisive factor for FACC was KAESER’s                                                                     The M171 comes standard with the SIGMA
                                                                                                                                                         CONTROL MOBIL controller which pro-               Many other features add to the user-friendli-
Because the compressed air must            ability to meet a mandatory specification,                                                                    vides variable pressure ranges between            ness of the M171 including an easy-to-read
be free of oil and water, four re-
frigerated dryers with energy              namely the ability to deliver compressed air                                                                  85 and 205 psig. Simple to operate, it auto-
                                                                                                                                                         matically adjusts the maximum air delivery
                                                                                                                                                                                                           but well-protected control panel, and large-
                                                                                                                                                                                                           neck fuel tank with overflow protection. The
saving control (TI 521 FE and
TE 141 models), two compressed
                                           free of oil and water.                                                                                        in each case allowing the compressor to
                                                                                                                                                         be precisely configured to actual demand.
                                                                                                                                                                                                           heavy-duty steel chassis, galvanized steel
                                                                                                                                                                                                           canopy and solid steel flooring protect the
air treatment lines with activated car-                                                                                                                  Additionally, SIGMA CONTROL MOBIL                 Deutz diesel engine and SIGMA PROFILE
bon adsorber (ACT 601) and two air-main                                                                                                                  also ensures machine-friendly start/stop          airend. In addition to the chassis-mount-
charging systems are integrated into the                                                                                                                 operation, provides valuable operational          ed models with height-adjustable tow bar,
system to ensure delivery of water and oil-                                                                                                              data, and alerts users when maintenance           skid-mounted versions are also available.
free compressed air in accordance with DIN                                                                                                               is needed.

The compressed air treatment also               The SIGMA AIR MANAGER 4.0 master controller with adaptive 3D pressure control allows the
applies the latest technical advances.          individual compressors to be switched on and off as conditions require.                                                                                                                       Designed to be user friendly on-site and during transport.

12 | KAESER report                                                                                                                                                                                                                                                                    KAESER report | 13
Report Spring 2019 - Kaeser Compressors
Images, above: Fuchs Group

The Fuchs Group – cultivating a world of good taste

Spice is the Variety of Life!
It is certainly not a new realization that food is about much more than nourishment. The experience of
flavors can represent pure enjoyment while enhancing our sense of culture and lifestyle. To attain the con-
summate taste experience, we need the right ingredients. The goal of Fuchs Group in Lower Saxony, with
its precious spices and spice mixtures, is to help turn a meal into a genuine culinary event.

                                                                                                                                                                                                                                                                                                    Image: Fotolia
Fuchs Group is Germany’s largest spice       tions in Abtswind and Hamlar (Bavaria),         From the life of a peppercorn                      ness when harvested, among other factors.       A special aromatic experience                    thorough quality check prior to the further
manufacturer and the world’s largest pri-    Melle (Lower Saxony) and Schönbrunn             The Fuchs Group’s most important pepper            Quality assurance accompanies the entire        Upon arrival in Dissen, the sacks of Bra-        processing steps. In the eight-story grind-
vately owned company in its industry.        (Schleusegrund, Thuringia).                     growing regions are in Brazil, specifically        process, starting in the field with the grow-   zilian peppercorns, along with other sacks       ing mill tower, the various herbs and spices
Established by Dieter Fuchs in 1952, it is                                                   in the northern half of this gigantic South        ing plant. After the harvest, the raw product   and transport packages containing a wealth       are cleaned, dried, ground, sieved, mixed
one of the biggest employers in its home     A tradition of partnership                      American country. Because the north of             is dried using the almost unlimited resource    of different herbs and spice plants from all     and placed in the final packaging in which
region. It has its headquarters in Dissen,   So, what is the company’s secret recipe for     Brazil is hot, like the south, but much wet-       of Brazilian sunshine, available 300 days       over the world, are placed in temporary          the finished product is sold.
in the state of Lower Saxony, at the edge    achieving maximum quality from the very         ter, it is ideal for growing pepper. The pep-      a year. This is followed by the next metic-     storage in the 108,000 sq. ft. warehouse.
of the Teutoburger Wald forest region.       start of the value chain? Careful selection     per plant is a perennial woody climbing vine       ulous quality inspection. Afterwards every      Catching the powerful fragrances pervad-         Compressed air in the service of
The product portfolio covers an unparal-     of the ideal growing regions for its products   that grows on trees, reaching heights of           sack of raw product is assigned a QR code       ing this space, visitors inevitably feel as if   gourmets
leled selection of spices, spice mixtures,   and close partnerships between Fuchs            up to 33 feet. When cultivated, the plant is       that permits tracking of “our” peppercorn       they have been transported to some far-off       Throughout the entire production process
herbs, spreads, pastes, sauces, dips and     Group employees and the farmers and             generally limited to a height of 10-12 feet.       every step of the way, from the field to the    bazaar. Amid this somewhat overwhelming          of the Fuchs Group, there is a unifying
many other ingredients for a healthy, cre-   contracting partners on the ground. The ex-     The small, unremarkable flowers grow on            in-store packaging. Now the peppercorn –        but highly aromatic sensory experience,          theme: compressed air. For every step in its
ative and varied cuisine with more than      change of ideas and experiences and the         spikes around 4 inches long, with 50 to 150        still whole at this point – can embark on its   one occasionally detects a familiar scent        operations, from the transport of the spices
8,000 products sold in over 60 countries.    transfer of knowledge benefits the suppli-      flowers per spike. After pollination, the fruits   journey to Germany.                             amongst the stored sacks and containers:         and herbs through to the cleaning, drying
Fuchs Group employs approximately 3,000      ers in the growing regions – and ultimately     (drupes) typically ripen within 8–9 months.                                                        oregano, cinnamon, paprika, nutmeg and –         and grinding processes, and to control the
people in 10 countries on four continents.   it enables the Fuchs Group itself to ensure     The various types of pepper (black, green,                                                         of course – pepper. From the warehouse,          machines and systems, the Fuchs Group
In Germany, the group has other loca-        consistent quality.                             white and red) differ by the degree of ripe-                                                       the raw materials are transported to another     needs compressed air. The company

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Report Spring 2019 - Kaeser Compressors
cannot afford any bottlenecks or disruptions
                 in the compressed air supply. The reliabili-
                 ty and availability of this universal energy
                                                                                                                                                                   Compressed air for the Institute of Thermal Turbomachinery
                 source is of paramount importance. When                                                                                                           at the Karlsruhe Institute of Technology
                 it was time to replace the obsolete com-
                 pressors from another manufacturer due
                 to increasingly frequent breakdowns and
                 problems, the obvious choice was the Co-
                 burg-based system provider KAESER. For
                 food processing operations, compressed
                 air must meet the highest quality standards
                 of Class 1.4.1 under DIN ISO 8573-1. The
                 Fuchs Group compressor room now houses
                 all of the equipment needed for energy-effi-
                 cient compressed air production in accord-
                 ance with those stringent requirements:
                 Two new-generation ASD 40 rotary screw
                 compressors with an integrated PTG 40-25
                 heat recovery system and two TE 102 ener-
                       gy-saving refrigerated dryers. The de-     The compressed air supply meets the stringent requirements of Quality Class 1.4.1
                                    cisive factor ensuring full   in accordance with DIN ISO 8573-1.
                                             compliance with
                                                Quality Class     mention the many friends of good cuisine,
                                                  1.4.1: the      who can now rest assured that the flavor
                                                  high-perfor-    specialists in Lower Saxony will continue

                                                          Because the new compressed air system
                                                        is highly efficient in terms of energy
                                                       consumption, it is a perfect fit for the Fuchs
                                                       Group’s sustainability strategy.
Image: Fotolia

                 mance KAESER filters connected down-             to supply them with high-quality herbs and                                                      The Institute of Thermal Turbomachinery at the Karlsruhe Institute of
                 stream from the compressors. In the con-         spices long into the future.                                                                    Technology (KIT) recently purchased an HSD 662 SFC rotary screw
                 text of the company’s sustainability efforts,
                 the new system also has a significant eco-
                                                                                                                                                                  compressor system. It will help to deliver compressed air to the exten-
                 logical impact. This makes the employees                                                                                                         sive experiment equipment and facilities in the research laboratories.
                 of the Fuchs Group very happy – not to
                                                                                                                                                                  For the experts from KAESER, the task of installing the new system
                                                                                                                                                                  posed substantial – but not insurmountable – challenges.

                                                                                                                                                                  In the Service of Research
                                                                                                                                                               The Institute of Thermal Turbomachinery          oratory, was planned and designed in the    al Church in Berlin, the German Embassy
                                                                                                                                                               is part of the mechanical engineering de-        1950s by the architect, furniture design-   in Washington and the office building for
                                                                                                                                                               partment at the KIT. The institute, including    er and former professor at the KIT, Egon    the members of the German parliament
                 Compressed air is needed in every step of        The air in the 108,000 sq. ft. warehouse is    The air-main charging system prevents over-   its research facilities, is housed in a former   Eiermann. Among the designs that earned     in Bonn. Defining features of the building,
                 product processing. Shown here: material         heavy with the scents of the many herbs and    loading the system and contamination of the
                 conveying.                                       spices stored there.                           compressed air network when the system is
                                                                                                                                                               experimental power station. The building,        Eiermann fame both in Germany and           with its east-west orientation, are the clear
                                                                                                                 restarted.                                    which today is used exclusively as a lab-        abroad were the Kaiser Wilhelm Memori-      structure, expansive glass surfaces and the
                 Images left and centre: Fuchs Group

                 16 | KAESER report                                                                                                                                                                                                                                                   KAESER report | 17
Report Spring 2019 - Kaeser Compressors
The rotary screw compressor system
                                                                                                                                                                                                      made a long and arduous journey: first,
                                                                                                                                                                                                      it was dismantled and lowered through
                                                                                                                                                                                                      the light shaft into the lower level of
                                                                                                                                                                                                      the building.

                                                                                                                                                      of a ship in a bottle. For shipping and in-
                                                                                                                                                      stallation, the selected system was initially
                                                                                                                                                      dismantled into its individual components.
                                                                                                                                                      They were then loaded onto a truck and, in a
                                                                                                                                                      two-day process,
                                                                                                                                                      lowered by crane
The body of the compressor unit had to be guided carefully through the light shaft.                                                                   into the base-        The HSD 662 SFC from KAESER KOMPRESSOREN
                                                                                                                                                      ment through the
                                                                                                                                                      light shafts. This    was selected as the center-piece of the high-pressure,
exposed steel skeleton – an unequivocally
modernist design. The building in which the
                                                  significantly reducing pollutant concentra-
                                                  tions in the exhaust gases they produce.
                                                                                                    without adequate access routes. It was im-
                                                                                                    mediately obvious that a standard product
                                                                                                                                                      was       followed
                                                                                                                                                      by assembling         high-temperature system.
laboratories are currently accommodated is        Numerous complex experimental setups              was out of the question. The institute was        the components
now a listed architectural heritage site.         are used to develop and evaluate new com-         searching for a reliable partner not only to      onsite in the compressor room on the lower
                                                  bustion concepts and cooling methods. The         provide a modern system meeting the de-           level of the institute. The compressor sys-
Research projects at the KIT                      advanced methods used include state-of-           sired specifications, but also with the ability   tem was commissioned just a week later,
The Institute of Thermal Turbomachinery           the-art laser technology to characterize the      to design and install a system around the         and has been performing its duties since
carries out many research projects in close       flow patterns typical of turbomachinery and       unique structural constraints of the building.    August 2018 – to the complete satisfaction
collaboration with partners from around           quantitative infrared thermography to detect      The resulting choice: a HSD 662 SFC rota-         of the institute’s management.
the world, including universities, research       surface temperatures.                             ry screw compressor system from KAESER
institutes and companies in the turboma-          These facilities require a reliable com-          KOMPRESSOREN. It now makes up the                 Images: KIT

chinery and automotive industries. The            pressed air supply. For some applications,        core of the high-pressure, high-temperature
research work conducted at the institute          the compressed air must be pre-heated to          system that supplies compressed air to the
under Professor Hans-Jörg Bauer centers           temperatures of up to 1562 °F.                    many research and experiment facilities of
around turbomachinery, and predominant-                                                             the Institute of Thermal Turbomachinery.
ly aircraft engines, gas and steam turbines       The main requirement: constant
for energy production, and turbocharg-            pressure and air flow                             So, how do you put the ship into
ers used in combustion engines. The re-           The previous compressor system had                the bottle?
searchers conduct experiments for which           reached the end of its service life and           The main hurdle to overcome before com-
they develop and implement advanced               needed to be replaced. The requirements           missioning of the system was the physical
measurement techniques and also apply             for the new system were as follows: it would      installation space. The compressor room is
the latest numerical methods to simulate          need to provide highly consistent pressure        not much bigger than the rotary screw com-
flow and heat transfer processes.                 and air flow at varying pressure levels and       pressor system itself and the only access
                                                  for fluctuating air delivery requirements. So     route open to the KAESER experts was
Key objectives of the institute’s research        far, so good. But there was a special chal-       through the hollow spaces below the light
activities are to improve the efficiency of fu-   lenge. The equipment had to be installed in       shafts on the outer facade. The undertak-         After being placed in the compressor room, the components were reassembled. Since then, the compressor has been doing its valuable work
ture aircraft engines and gas turbines while      the lower level of a listed historical building   ing was not unlike the proverbial placement       to the complete satisfaction of the institute’s management.

18 | KAESER report                                                                                                                                                                                                                                                         KAESER report | 19
SIGMA AIR UTILITY at Neoperl GmbH in Müllheim                                                                     The joint Swiss/German family company           Practical and beautiful                        pany knows the plumbing conditions on
                                                                                                                                   Neoperl was founded in Reinach-Basel in         Millions of people use Neoperl products        the ground like the back of its hand: water

                 The Beauty of Water
                                                                                                                                   1959. In 1961, the Group’s German head-         every single day. For example, the jet regu-   hardness, water pressure, lime content, im-
                                                                                                                                   quarters, Neoperl GmbH, was established         lators can be found today on virtually every   purities, construction methods and national
                                                                                                                                   in Müllheim. The owner-managed, medi-           outlet fitting on washbasins and bathtubs.     standards. The products are adapted to the
                                                                                                                                   um-sized business is the world’s leading        They shape the water into a splash-free        local conditions in the on-site production
                                                                                                                                   supplier for the plumbing industry with sales   stream and make it pleasantly soft by draw-    plants.
                                                                                                                                   subsidiaries in every corner of the globe,      ing air into the flow. Moreover, they reduce
                                                                                                                                   wherever its customers are based.               the fitting’s noise, help conserve water and   To ensure proximity to its customers
                                                                                                                                                                                   save on energy costs.                          throughout the world, the international com-
                 Can water be aesthetic? Absolutely! At any rate, the German-Swiss family business Neoperl ensures that            The success story began over half a cen-                                                       pany employs approximately 1800 staff in
                 it flows in a highly aesthetic way. Neoperl products shape the water stream, regulate the flow rate and           tury ago. Over the years, the company has       Aesthetics also take center stage. In 2016,    17 countries. The extensive logistics infra-
                                                                                                                                   developed a wide range of sanitary prod-        the product design of the Mikado aerator       structure consists of 12 production plants in
                 protect water from contamination. And although they can be found in use with just about every washba-             ucts, which currently
                 sin, bath or kitchen fitting, they spend their useful lives languishing in near-obscurity as they are virtually   includes aerators,
                                                                                                                                   flow       regulators,
                 invisible.                                                                                                        check valves, di-
                                                                                                                                   verters, connecting
                                                                                                                                                             The advantages of a SIGMA AIR UTILITY
                                                                                                                                   hoses and shower
                                                                                                                                   hoses, together with
                                                                                                                                                             are clear: there is no investment outlay,
                                                                                                                                   various accessories.      and operating costs can be precisely calculated.
                                                                                                                                   One of the mile-
                                                                                                                                   stones in the com-
                                                                                                                                   pany’s history was
                                                                                                                                   the first noise-reducing aerator, which was     won the Red Dot Award for its extraordi-       Europe, Asia and the United States, as well
                                                                                                                                   developed in the 1970s. During the 1980s,       nary, grid-like spray pattern, formed by the   as sales subsidiaries in all key markets.
                                                                                                                                   the Neoperl Group introduced its long-life      geometric arrangement of individual water
                                                                                                                                   technology and, in the 1990s, launched the      jets.                                          Success needs space
                                                                                                                                   world’s first aerator without a wire mesh.                                                     The world market leader in the sanitary fit-
                                                                                                                                   Today, Neoperl supplies products and            Different regions,                             tings sector has had an outstanding track
                                                                                                                                   spare parts to the world’s leading fittings     different conditions                           record for over 50 years. This means that
                                                                                                                                   manufacturers, technical OEMs and the           Drinking water networks have unique fea-       space is sometimes tight in the buildings
                                                                                                                                   wholesale and retail trade.                     tures in every country. With subsidiaries in   on the company’s 15 acre site. Therefore,
                                                                                                                                                                                   the customer’s country of origin, the com-     the production area has been extended to
Image: Fotolia

                                                                                                                                                                                                                                                            KAESER report | 21
Compressed air at a fixed price
                                                                                                                      Ideally customized to meet all of these
                                                                                                                      criteria, the modern compressor system
                                                                                                                      includes several different rotary screw
                                                                                                                      compressors: one CSD 105, three CSDX
                                                                                                                      165 and one CSDX 165 SFC. Three down-
                                                                                                                      stream TF 340 refrigerated dryers dry the
                                                                                                                      compressed air to a Class 4 pressure dew
                                                                                                                      point in accordance with ISO 8573-1. The
                                                                                                                      SIGMA AIR MANAGER 4.0 master control-
                                                                                                                      ler calculates the perfect compressor com-
                                                                                                                      bination to meet current requirements. The
                                                                                                                      entire unit is housed in a container located
                                                                                                                      outside the production halls. As a result, the
                                                                                                                      ventilation ducts are also outside, meaning
                                                                                                                      fewer pipelines were needed to set it up,
                                                                                                                      while outdoor installation is better from a
                                                                                                                      fire safety perspective.
Image: Neoperl GmbH

                                                                                                                      Commissioned just a few months ago, the
                                                                                                                      operator is already highly impressed with
                                                                                                                      the new station. After just four weeks of
                      The Müllheim production site uses compressed air as an energy source for every aspect of        operation, the first before-after calculation
                      its manufacturing operations.                                                                   produced impressively gratifying results!
                                                                                                                      Energy consumption is down by approxi-
                      include a new manufacturing hall. Since the     pressed air requirements. Following nu-         mately 15% compared to the previous com-
                      Müllheim production site uses compressed        merous discussions, site inspections and        pressor system.
                      air as an energy source for every aspect of     telephone conferences, it soon became
                      its manufacturing operations, a dependa-        clear that the solution that best met Neop-

                                                                                                                                                                                                                                                                                                                Image: AutoGyro GmbH
                      ble supply of quality compressed air with       erl’s needs and requirements was a SIGMA
                      precisely defined parameters is essential.      AIR UTILITY model. The advantages of this
                      In addition, some of the compressors in         station are crystal clear: the customer has
                      the existing compressed air stations were       no capital outlay, the running costs can be
                      obsolete. These also needed replacing           calculated in the form of a fixed basic price
                      as part of the modernization program. As        and maintenance is covered by KAESER’s
                      a first step, an air demand analysis (ADA)      service package – at zero additional cost.
                      was carried out to calculate the exact com-                                                                                                      Premium quality craftsmanship in series production: AutoGyro GmbH, Hildesheim

                                                                                                                                                                       The Sky’s the Limit
                      The KAESER SIGMA AIR UTILITY station:
                      Left: Interior view – configuration of the compressors and dryers.
                                                                                                                                                                       The inventor of the gyroplane, Juan de la Cierva, came very close to realizing this dream when he took
                      Right: Exterior view of the station.                                                                                                             to the skies with his ‘autogyro’ for the first time almost one hundred years ago. Powering the rotor by
                                                                                                                                                                       means of autorotation, rather than the helicopter’s use of active rotation, his invention revolutionized the
                                                                                                                                                                       world of aviation.

                                                                                                                                                                       From a garage workshop to the               loped himself. He turned his hobby into a    AutoGyro GmbH. He teamed up with two
                                                                                                                                                                       world market leader                         career by establishing his own business in   friends to develop his first fully functional
                                                                                                                                                                       Even as a child, Otmar Birkner, the foun-   Gehrden in 1995, High Tech Composites        aircraft, which received a type certificate
                                                                                                                                                                       der of AutoGyro GmbH in Hildesheim, was     (HTC), which specialized in manufacturing    in 2004. Three years later, the first “Auto-
                                                                                                                                                                       passionate about developing and building    composite (plastic) parts, such as pro-      Gyro” went into series production. Since
                                                                                                                                                                       model aeroplanes. In his parent’s gara-     peller blades. However, that was just the    then, other models gradually followed eve-
                                                                                                                                                                       ge, he laminated his own first propeller    beginning. In 2000, the company moved to     ry few years: the “Calidus” in 2009 and the
                                                                                                                                                                       blades, made in moulds that he had deve-    Hildesheim, where Otmar Birkner founded      “Cavalon” in 2011, subsequently garnering

                      22 | KAESER report                                                                                                                                                                                                                                                  KAESER report | 23
the Red Dot Design Award in 2012. Last
                                                                                       year, the exceptional design of the sleek
                                                                                       planes received yet another accolade. The
                                                                                       “MTOsport” won the coveted “Best of the
                                                                                       Best” 2018 Red Dot Design Award, which
                                                                                       officially attested to the ultra-light aircraft’s
                                                                                       “innovative symbiosis of aesthetics and
                                                                                       function”.

                                                                                       On course for success
                                                                                       Since its foundation, the gyroplane special-        Compressed air is used to power almost every production stage.                                      The gyroplane before the rotor is fitted.
                                                                                       ist has reported steady growth and today
                                                                                       employs a 100-strong workforce. From the
                                                                                       first brushstroke of the draft through to the
                                                                                       test flight, the majority of the components         ristics, making it one of the safest aircraft      “We use compressed air in all areas
                                                                                       for the ultra-light AutoGyro (aside from the        of all. Unlike fixed-wing aircraft, there is no    of production”
                                                                                       engine and a few instruments) are manu-             danger of stalling or tailspin. Even in the        Ninety percent of the components are ma-
                                                                                       factured completely in the production facili-       event of engine failure, the Autogyro re-          nufactured and assembled with pinpoint
                                                                                       ties at Hildesheim Airfield by the highly qua-      tains full control capability and merely loses     precision in the on-site production facilities
                                                                                       lified team of technicians and engineers.           altitude slowly as it is still able to perform a   both by hand and with state-of-the-art CNC
                                                                                       With sales partners in over 42 countries            controlled landing. Almost like no other ro-       machines. Most of the production stages
                                                                                       around the world, numerous flight schools           torcraft, the Autogyro can even be flown in        require compressed air, from spray painting
                                                                                       and service locations, and the gyro factory         strong winds and can be used practically all       to grinding or pressing processes. The orig-
                                                                                       at its Hildesheim headquarters, AutoGyro            year round. As extreme low speed is pos-           inal compressor station includes an
                                                                                       serves a worldwide network with the aim of          sible, the gyroplane is ideal for excursions       SK 24 and a compressor from another ma-
                                                                                       combining safety and the gyro’s unlimited           and day trips. Moreover, the sky’s the limit       nufacturer, “which ultimately kept causing
                                                                                       versatility for the pure joy of flying. Global-     when it comes to the design. It can be cu-         problems, unlike the KAESER compressor,”
                                                                                       ly, some 3000 autogyros are deployed on a           stomized in any way, from a company logo           reports René Stecher, the factory foreman
                                                                                       variety of missions, ranging from the Qatar         to a family coat of arms or a distinctive color    responsible for the compressed air system.
                                                                                       Royal Guard to Australia’s “Shark Patrols”          coating.                                           A new unit was needed. Given the excellent
                                                                                       and partners for adventure trips in Namibia.                                                           track record of the first KAESER compres-
                                                                                                                                           The company even received an un-                   sor, the obvious solution was to purchase
                                                                                       Fly like Icarus, but safely                         usual commission to embellish an                   an additional SM 12.
                                                                                       Attracting a good deal of attention, the            AutoGyro with gold leaf and Swarovski
                                                                                       secret of the rotorcraft’s growing popula-          stones, recalls Judith Reichardt, who is re-       Four years ago, the system needed to be
                                                                                       rity lies in its innovative drive technology.       sponsible for marketing and communicati-           expanded once again since compressed air
                                                                                       Although the gyro resembles a helicopter,           on. Best of all, the innovative rotorcraft runs    was also needed on-site for the assembly
                                                                                       the rotor uses the air stream – rather than         at one tenth of the cost of operating a heli-      line in the plastics processing department
                                                                                       an engine – to start the rotation process           copter. Depending on the road traffic regu-        located across the road. Two more SM 12
                                                                                       passively. Known as autorotation, this ge-          lations, in some countries you can even roll       AIRCENTERs were installed for this pur-
                                                                                       nerates the buoyancy of the gyroplane. The          up to a service station and fill up with Super     pose. A wise decision as the system now
                                                                                       aircraft is driven by a propeller engine.           Plus fuel, Judith Reichardt adds.                  runs “smoothly and to our complete satis-
                                                                                       Thanks to its design, the gyrocopter flies                                                             faction,” according to René Stecher.
                                                                                       with very special and unique characte-
Approximately 90% of the components are manufactured on-site.

                                                                                                                                                                                                     From spray painting to grinding,
                                                                                                                                                                                                     and from pressing processes to CNC
                                                                                                                                                                                                     machining, most production stages
                                                                                                                                                                                                     require compressed air.

Emphasis is placed on maximum precision      The tail units are also produced in the   Final cockpit assembly: installation and            The KAESER station provides the necessary
in the individual production stages.         factory at Hildesheim Airfield.           connection of the aircraft’s avionics equip-        supply of compressed air.
                                                                                       ment.

24 | KAESER report                                                                                                                                                                                                                                                        KAESER report | 25
Author: Beth Wood

Long-term customer satisfaction: Koudsy Body Works (KBW), Australia

Prestige Vehicle Repair and Customization
For over 35 years, Koudsy Body Works                  In Australia’s New South Wales,
(KBW) has been one of the leading special-
ists for all kinds of vehicle repairs, includ-        where Koudsy Body Works
ing both cars and motorcycles. One glance             (KBW) is based, the family-
at the photo gallery on their homepage is
enough to set the pulse racing of any cus-
                                                      owned business has gained an
tomer with a weakness for luxury models               outstanding reputation, not just
or vintage cars – the family business also            for its vehicle repair and resto-
specializes in the restoration of classic ve-
hicles and car customisation. Extensive in-           ration services, but also for its
terior and exterior modifications are carried         exclusive car styling packages.
out with meticulous attention to detail. From
black styling packs to spoiler/body kits, ex-
haust systems or wheel and tyre packages,
automotive fans of all vehicle makes and
models have choices galore!

Compressed air an integral part
Koudsy Body Works provides the very
highest level of service. It is important to
management that their team is always up-
to-date with constant training and that state-
of-the-art machinery is made available.
After all, the company’s philosophy is that

                                                                                                                                                                                                                                                                             Images: KBW
“Every vehicle will leave looking better
than before.” From powering air tools to
the spray paint booth, compressed air is
an integral part of the operation. Therefore,
it is no surprise that air production is also    work. Especially for the spray painting side    the quality of the finish, but would also be               some time now and it continues to operate
expected to meet the very highest stand-         of the business, without quality and reliable   costly to re-do. We pride ourselves on the                 reliably and efficiently for us,” he explained.                Without compressed air,
ards. Just over a decade ago, an aging           compressed air, we cannot function. The air     quality of work we do and it is essential that
compressed air system prompted Charles           needs to always be clean with no moisture       we use quality equipment. We have had the                                                                                 the repair shop grinds to a halt.
Koudsy, the manager at KBW, to inspect           in the line. This would not only jeopardize     KAESER compressed air system for quite
the entire air center and review the com-
pressed air requirements. When it came to
purchasing a new compressor that was both
powerful and reliable, the obvious choice
was an AIRTOWER 11 from KAESER
KOMPRESSOREN. The compact com-
pressor solution incorporates a rotary screw
compressor and refrigerated dryer a single
package, thus keeping space requirements
to an absolute minimum – a key criteria in
the vehicle repair industry.

An oldie but a goodie
Managing Director Charles Koudsy is de-
lighted to report that the system has oper-
ated reliably for over ten years. “If our com-   Compressed air is indispensable in powering the tools used in the car repair    Powering the air impact wrench...                                            ...and the spray paint booth.
pressor doesn’t work, our business doesn’t       shop.

26 | KAESER report                                                                                                                                                                                                                                      KAESER report | 27
KAESER KOMPRESSOREN at bauma 2019

The World’s Largest Trade Fair                                                                                                                                                                   Booths FM.708/15 and FM.708/17.

      This year, the 32nd iteration of the world’s leading trade fair for construction machinery, building                     Industrie 4.0 also for portable                 even stricter statutory emission limits. For   of the entire KAESER MOBILAIR product
                                                                                                                               compressors                                     the first time, a particle number limit is     range: portable compressors with flow rates
        material machines, construction vehicles, equipment and mining machines will take place at                             Dubbed the ‘Fourth Industrial Revolution’,      also being introduced for machinery with       from 35 to 1624 cfm and power classes from
              the Neue Messe München exhibition grounds in Bavaria, Germany, from the 8th to the                               the phenomenon of human-machine in-             a power range from 19 kW, necessitating        7.5 kW to almost 450 kW, from the small,
                                                                                                                               teraction and the on-demand availability        exhaust after-treatment systems in the         compact M13 compressor right up to the
                    14th of April. Some 3,400 exhibitors from almost 60 countries will present the entire                      of all data will be more widely used in the     portable compressor class. How KAESER          oil-free compressed air giant M500-2.
                         range of construction machinery, vehicles and hand tools available on the                             civil engineering and construction sectors      closed the gap between the market de-          When it comes to alternative drives to the
                                                                                                                               in the future. It is reassuring to know that    mand for light, compact, portable compres-     diesel engine, the line-up will also include
                            market. As the leading industry hub, bauma sets the trends for the future.                         KAESER’s MOBILAIR portable compres-             sors and the additional weight of the larger   electric drive and gas engine models, while
                            However, the trade fair is not just geared towards technical specialists but is                    sors can be equipped with the necessary         diesel particulate filters and radiators re-   KAESER will unveil the large-scale M255 E
                           also open to the public.                                                                            technology. It comes as no surprise, then,      quired by the exhaust after-treatment, will    compressor designed especially for the
                                                                                                                               that ‘The smart construction site’ is a major   be revealed at bauma 2019. We will be pre-     compressed air hire sector.
                                            Huge cranes, colossal excava-       advantage of the platform at the last show     focus at the KAESER exhibition stand.           senting the next generation of lightweight
                                            tors and the latest technology      in 2016 to do business and learn about                                                         MOBILAIR portable compressors, featuring       Visit bauma in Munich and discover a host
                                             trends – anyone who is in          specific key topics. The fair features live    Visitors can take an up-close look under the    an aluminium body, and brand new design        of exciting innovations and technology
                                              any way active in the con-        demonstrations of the machinery and its        enclosure of the exhibits, or keep a watchful   features.                                      trends. The compressed air experts from
                                                struction industry will gath-   different applications. Experts advise the     eye on remote machines in real-time using                                                      Coburg look forward to welcoming you at
                                                  er at bauma 2019, where       visitors on the latest developments, while     the MOBILAIR Fleet Management online            The new models in the proven MOBILAIR          Booths FM.708/15 and FM.708/17. The
                                                  the leading trade fair for    the panel discussions and conferences          tool to access current operating data, eval-    portable compressor series – M55, M59 and      tower of MOBILAIR MODELS with colored
                                                  construction and build-       keep the trade audience up to date on a        uate machine performance, find out when         M65 – will also premiere at bauma 2019;        PE enclosures will guide your way straight
                                                  ing materials machinery       wide range of subjects.                        the next service is due or pinpoint their lo-   highly environment-friendly, their             to KAESER.
                                                  will showcase the new-                                                       cation. Moreover, the platform helps users      innovative motors comply
                                                  est trends and devel-         A trade fair of superlatives                   plan operations, manage the accounts and        with the new EU Stage V
                                                  opments in the sector.        It is the record exhibition space that makes   document the work performed. Plus, re-          and the US final Tier 4
                                                  Since its inception more      bauma in Munich the world’s largest fair.      mote diagnostics capability saves valuable      standards. Visitors will
                                                  than 50 years ago, bau-       It occupies every hall at Neue Messe           time when servicing is required.                find a broad overview
                                                  ma has garnered a rep-        München, as well as the outdoor area,
                                                  utation as the driver of      which was extended especially for the          Innovations in the
                                                  innovation and success        show. This equates to a huge 6,500,000         portable compressor programme
                                                  in the global construc-       sq. ft., divided into 1,900,000 sq. ft. hall   According to the new
                                                  tion machinery industry.      space and 4,500,000 sq. ft. outdoor space.     EU Stage V European

                                                                                                                                                                                                             Networking
                                                  This view was shared          The target markets are industry, trade, ser-   emission standards, as
                                                  by the over 600,000           vice providers in the construction and con-    of 2019, construction
                                                  visitors from more than       struction materials industry, plus             machinery will be re-

                                                                                                                                                                                                               @ MOBILAIR
                                                  200 countries who took        key procurement players.                       quired to comply with

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