Turnkey compressed air container: design, implementation and energy saving in one package
What looks like an ordinary 40-foot shipping container on the outside hides cutting-edge technology inside.
Can a compressed air station be built in a container in a way that improves energy efficiency and increases production reliability? Juha Tuomainen Oy's project shows how a modern compressed air system can be designed and implemented from start to finish - turnkey.
A machine shop requiring special precision
Juha Tuomainen Oy is a machine shop focused on special grinding, manufacturing precision components for the technology industry – from drive shafts for sports cars to cylinders for rock drilling equipment.
- hundredths of a milliliter
- up to thousandths of a millimetre
For comparison: a dust particle is often 0.01–0.02 mm.
In this type of production, the quality and reliability of compressed air are critical.
Container solution for compressed air station
A 40-foot shipping container catches the eye in the company's yard. Ordinary on the outside – a modern compressed air station on the inside.
- machining centers
- in cleaning parts
- daily 5 am–10 pm
The goal was to build a solution that:
- ensure uninterrupted production operations
- reduces energy consumption
- improve working conditions
Project objectives
SmartAir was responsible for the entire project from design to implementation. The goals were set as follows:
- ensuring the availability of compressed air
- significant energy savings
- compressed air station automation
- waste heat recovery
- improving working conditions (noise, heat, air quality)
Planning determines the outcome
Inside the container, all systems were designed as a single entity: compressed air lines, ventilation, electricity, automation, and layout and placement.
Precise layout design ensures a clean finish and easy maintenance.
- as neat installations
- easier maintenance
- as energy efficiency
Automated ventilation and control
Responsible for the automation of ventilation Fidelix Ltd.. The site used the Fidelix FX-Spider-X system, which controls ventilation dampers, compressor operation permissions, and temperatures.
The Fidelix system controls ventilation and compressors.
Winter: The heat produced by the compressors is utilized for hall heating.
Summer / Control mode: Controlled heat removal and optimization.
In addition, a signal post was installed in the hall:
Green = system OK
Red = fault condition
Old vs new compressed air system
Previous solution: fixed-speed oil-lubricated screw compressor (functional, but less energy efficient).
New solution: energy-efficient frequency converter-controlled compressor (optimization according to actual consumption).
Energy consumption comparison
| Solution | Energy consumption |
|---|---|
| Old system | ~17.4 kWh |
| New system | less than 8 kWh |
The system runs approximately 4,500 hours per year.
Annual savings:
- -energy savings: ~46,800 kWh
- -corrected net savings: ~40,700 kWh
- -financial savings: ~5000 €/year
Savings in concrete terms
With annual savings you could, for example:
- buys ~69 bottles of champagne per year
- heats 1–4 electrically heated detached houses
- heats an electric sauna for decades
Waste heat for use
The solution utilizes the heat from the compressors in winter. As waste heat is reduced with energy efficiency, it is compensated with air source heat pumps (COP ~3).
Turnkey design team
SmartAir was responsible for the entire chain: dimensioning, equipment tendering, diagrams, piping and automation, and contractor coordination.
Included in the project: Orivesen Insulation Ltd, Avitor Electricity Ltd, Fidelix Ltd, Ascora Ltd.
Sami Uusi-Erkkilä (SmartAir) and Aarne Tuomainen shake hands over a successful project.
What can be learned from this?
- SMEs can also make big savings.
- Compressed air is often an underutilized optimization target.
- Comprehensive planning pays for itself.
Are you planning a similar project?
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