Reducing Compressed Air Consumption in Beverage Manufacturing | Case Study

Reducing Compressed Air Consumption in Beverage Manufacturing | Cases Study - bottle plant - Parker Pneumatics Division Air blowing activities consume almost half of all compressed air used in beverage plants and can often become an unrecognized burden on a business’s resources.

One of the largest soft drinks manufacturing businesses in China, Hangzhou Hongsheng Beverage Group, took a proactive approach to reduce this consumption by utilizing a new air saving solution. In doing so, they benefited from a substantial 45% reduction in compressed air consumption.

The background

With several hundred production lines across the country, Hangzhou Hongsheng Beverage Group is continually looking for ways to improve their performance and social responsibility, and approached us to provide a solution to help them reduce their air consumption in their manufacturing processes.

We recommended the Air Saver pneumatic valve as the ideal way to reduce energy consumption, decrease production costs and align the business with China’s sustainable development strategy. As a totally integrated solution, the Air Saver system, comprised of the ASC500 Air Saver valve, Global FRL Air Preparation System and Legris tubing and connectors, delivered a significant saving on their compressed air consumption and CO² emissions.

Reducing Compressed Air Consumption in Beverage Manufacturing-Case Study-Group Hardware Air Saver Valves-Pneumatic Division Europe-Parker Hannifin Corporation

Designed to maximize the removal of particles more efficiently in PET bottle plants, the ASC500 Air Saver unit can be utilized in a range of ways. During the blow moulding process, each blast of the pulsing ionised blow agitates unwanted waste particles for more efficient removal and reduced cycle time. Plus it can also be utilized for an assisting blow to convey bottles, as an escape blow for when the line has stopped and before pasting labels on them; delivering greater production line efficiency, increasing plant productivity and overall quality.

Utilizing innovative pulsed air technology to reduce air consumption and improve plant efficiency in air blow applications, at its core is a switching valve that converts continuous air blow into a more effective pulsed air blow without the need for any additional external control. Put simply, it creates air that is blown in a series of high speed on and off pulses; when the blow is off, there is no air consumption, resulting in fewer tank recharging cycles.

Alongside benefiting from a more efficient particle removal solution, Hangzhou Hongsheng Beverage Group saw a sizable 45% reduction in air consumption and associated costs for energy use. With no changes to the PLC programm, the Air Saver Unit has proven to be a cost-effective solution that was retrofitted to their existing production line, providing an immediate reduction in air consumption without any further cost outlay.


Following this simple installation and setup, Hangzhou Hongsheng Beverage Group saw instant improvements in performance results with a quick return on their investment.

Air Saver is designed to improve overall plant production without a significant capital investment and the technology has exceeded our—but more importantly our customer’s— expectations on this application. The reliability and scalability of the unit will support the beverage business in maximizing their productivity plus the easy installation ensured production was uncompromised.

Learn more

Learn why the Air Saver valve has been nominated as Product of the Year for 2016 by Plant Engineering and cast your vote.


Reducing Compressed Air Consumption in Beverage Manufacturing - Case Study - Harry Vlap-Pneumatic Division Europe-Automation Group-Parker Hannifin CorporationThis article was contributed by Harry Vlap, European product manager for industrial application products, Pneumatic Division Europe,  Parker Hannifin Corporation.





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