Gulf Construction Online - Firm set to secure global position

Compressors

Firm set to secure global position

Having just completed a year as an independent business, major compressor manufacturer CompAir is in a buoyant mood as it elaborates on the measures taken by the firm to secure its leadership position in the global market since its restructuring.

01 October 2003

CompAir, one of the world's leading names in compressed air technology, has been restructured and declares itself ready to return to the centre stage.

Over the past year, the company - considered to be the third largest in its sector - has launched a range of equipment to meet market demands and strengthened its global network.
While as a business, there had been doubts about CompAir's future under its previous ownership, now just one year since the company secured the private funding to become an independent operation, it is totally reinvigorated.

During the past year, CompAir has seen a major restructuring of its business into market specific divisions, together with a rationalisation of some of its production facilities. While getting the business back into competitive shape has been the main priority, the company also has been making great strides in better understanding what customers want in terms of product and in looking at strategic growth in key global markets, including the Middle East.

Customer focus
With the customer in mind, CompAir's global activities have been restructured into five product-based divisions: industrials, high pressure, portables, aftermarket, and AirWorx contract management services. Each division has its own management structure and operates as an autonomous business with a clear emphasis on its specific markets and the needs of its customers.

Portable equipment, primarily destined for the construction industry, accounts for some 25 per cent of CompAir's business and in this division, effort has been concentrated on the development of a 'globalised' range of portable products capable of being tuned to local market needs. With a range comprising more than 50 models, there is something to suit any application, from the smallest 2 cu m/min 7 bar-rated single axle model powering a single pneumatic tool, through to twin-axle models with flow rates to 42 cu m/min and pressures to 24 bar.

Turbo screw range
Perhaps the most significant recent development in the construction equipment market has been the introduction of a range of lightweight, fuel-efficient turbo screw portable compressors.
The C-TS series is based on a patented turbo screw compression system that offers significant improvements on fuel economy compared with a conventional portable compressor. The turbo screw solution uses a Cummins turbo-assisted engine powering both a CompAir screw compressor and an engine exhaust gas-driven turbine which pre-compresses the suctioned inlet air before it enters the compression chamber.

Pre-compression means that effectively the compressor becomes a two-stage machine and, due to a lower compression ratio, less energy is used by the air end to compress to the final working pressure as the inlet pressure is higher. As it is the exhaust gases that drive the turbo, the pre-compression comes 'free of charge'. Energy efficiency is also enhanced by an intercooler between pre-compression and compressor air intake.

Offering top output in the C-TS series is the C210TS-9, which delivers 21 cu m/min of air at 9 bar, with higher pressure derivative models also available. The fuel savings on the C210TS-9 are impressive when compared with a conventional compressor of a comparative size - some 27 per cent. At only 3,280 kg, this model is also engineered to be the lightest in its operational class, making it easy to transport and position on site. It is, in fact, light enough to be towed by a 4 by 4 vehicle.

Also in the range are the C160TS-12 and C180TS-9, designed for blast cleaning, light drilling and on-site power applications. The C160TS-12 provides 16 cu m/min of air at 12 bar delivery pressure, whilst the C180TS-9 delivers 18 cu m/min at 8.6 bar. Built to the same dimensions, both models are engineered to be lightweight and easy to handle.

In line with CompAir's policy of developing its global product range, the turbo-screw concept has been extensively tested in field trials, which took place across five continents at extremes of temperature, altitude and environmental conditions.

New products
Further product developments for the construction market were unveiled earlier this year at Intermat in Paris. These include a new six-model range providing a variety of air pressures at 9, 12 or 14 bar designed for a wide range of general applications including blast cleaning, small-scale drilling operations and the provision of air power to construction sites.

The 8.5 to 13 cu m/minute compressors are powered by Deutz water-cooled four-cylinder turbocharged engines. The C110-9, C95-12 and C85-14 use the BF 4M 2012C engine, providing 11.3 cu m/min of air at 8.6 bar, 9.5 cu m/min at 12 bar and 8.5 cu m/min at 14 bar pressure, respectively. The larger output models use the BF 4M 1013 EC Deutz diesel and these include the C140-9, which provides 13.3 cu m/min at 8.6 bar, the C115-12, providing 11.6 cu m/min at 12 bar and the C105-14, providing 10.6 cu m/min at 14 bar. Both engines comply with the latest European and US exhaust emission regulations. Designed for global application, the entire range has an ambient temperature capability of -10 deg C to 50 deg C.

Various features are designed into these new generations of portable compressors to ensure long and reliable operation. These include a large-capacity see-though plastic fuel tank that allows a minimum of nine hours full-load operation or up to 15 hours of intermittent working. Separate high-capacity air filters, for both engine and compressor unit protection, have an additional inner safety cartridge which increases durability in dusty environments. In operation, the machines are protected by a range of automatic shutdown systems including automatic low fuel shutdown, to help prevent costly call outs for engine repriming. A starter interrupter system prevents attempts to use the starter as a priming pump after low fuel shutdown.

Options include a 7 kVA 110 volt electric generator with a high level of dust and water ingress protection (IP54) on the C110-9, C95-12 and C85-14 models. A built-in aftercooler with water trap is also available and compressed air treatment with built-in microfilters can be added. For operation in gas and oil installations, an exhaust spark arrestor is available and a Chalwyn engine overspeed protection valve option provides protection in the event of ingestion of escaped inflammable process gas.

Strengthened presence
With these significant product developments underpinning its support of the construction industry worldwide, CompAir is also committed to expanding its presence in key global markets. The company has already made two acquisitions designed to strengthen its presence in Australasia and the US and over the past year, it has also launched a number of strategic initiatives in Asia.

In the Middle East, CompAir already has a long record of success, which includes supplying large numbers of units to all of the GCC countries through its distribution and service network. Since the launch of the new C110-9 machine (11.3 cu m/min of air at 9 bar), CompAir Middle East has experienced an escalating demand, a clear illustration of the importance of incorporating design features that meet the harsh conditions experienced within the region.

The initial feedback from both owners and operators is very positive and pleasing. Not only have the operational abilities of the compressor met with approval, comments are also being received on its sleek design, making it what has been described as 'the best looking machine in the compressor industry today'.

Of course, the major current concern in the region is the rebuilding programme in Iraq. CompAir Middle East has been actively involved with all the parties participating in the reconstruction activities in Iraq and has taken the initiative early on to ensure an adequate supply of portable compressors was readily available. These machines are being held in Kuwait in readiness for immediate transportation to any site within Iraq.

Steve Ryder, regional sales director for CompAir Middle East comments: 'The rebuilding programmes, be they roads, schools, hospitals, power or water, are essential for the Iraqi nation's renaissance and we are delighted that our machines are available and being used extensively by the contractors undertaking these projects.'
As well as providing support for the necessary construction programmes in Iraq, CompAir Middle East is also making preparations for the anticipated high demand, that will follow, for the rehabilitation of the large industrial air compressors used in the country's process industries.

CompAir Middle East's portable distribution partners have welcomed the renewed market focus that has been initiated and they, in turn, are undertaking to provide the highest levels of customer satisfaction within the industry. Aftermarket support and service are seen to be key ingredients in this and as Ryder states: 'Market plans have been prepared to ensure that CompAir's global service quality is available in each of the Middle Eastern territories.'

Over the last year, the pace of change within CompAir has been remarkable. The spotlight is now clearly on customers to whom the company has made the commitment to bring more new products to the market more quickly. A growing global sales network will ensure that CompAir's products are fully supported in the field and that the company is able to gain a closer understanding of individual markets.