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TECHNICAL BRIEF · WILLEE EDITORIAL
Purpose and scope
Compressed air is an operating input that should be measured against useful liquid delivery. This Willee technical brief provides a comparison method for an existing WILDEN installation and a candidate configuration. It is independent editorial guidance, not a manufacturer white paper, a field-test report or a promise of savings.
Define an equivalent service
Set the required liquid volume, transfer time, discharge condition and acceptable product quality. Record viscosity, temperature and suction level. Compare pumps while delivering the same service. If one trial transfers less liquid, the lower air consumption alone does not demonstrate better efficiency. Include startup, empty-vessel intervals and production stops if they are part of the normal duty.
Measure the boundary consistently
Use a suitable calibrated air meter and document whether it reports normal, standard or actual volume. Do not mix these units without a documented conversion basis. Measure at a consistent system boundary and record running supply pressure. Shared air users, leaks and meter installation requirements can distort the result; an instrument or compressed-air specialist should review the measurement setup.
| Record | Why it matters |
|---|---|
| Liquid volume and batch time | Confirms equivalent useful output |
| Air volume and reference conditions | Keeps meter units comparable |
| Running pressure and fluid condition | Explains changes between trials |
| Annual batch count and site air cost | Converts the trial into a transparent estimate |
Calculate a transparent estimate
For a defined duty, air cost equals measured air volume multiplied by the site cost per unit of air. Annual cost is the sum across relevant operating modes, using their actual hours or batch counts. Use a site-specific air cost from the plant energy team. If it is unknown, present a range rather than inventing a universal conversion from air volume to electricity.
Worked arithmetic, not product performance
Suppose a measured baseline uses 12 normal cubic metres per batch and a trial uses 9 under equivalent conditions. The difference is 3 per batch, or 25 percent of that baseline. At an illustrative 4,000 batches per year, the difference is 12,000 normal cubic metres annually. Multiply by the verified local cost per normal cubic metre. These invented values only demonstrate the arithmetic; they are not WILDEN test results.
Evaluate a SHIFT proposal
Pro-Flo SHIFT uses an air-control feature intended to avoid overfilling the air chamber. Evaluate a proposed installation at the required duty and document the basis of any estimate. A headline maximum percentage is not a substitute for measurements. Confirm that changes in air-line condition, suction restrictions or operating practice have not been incorrectly credited to the pump alone.
Turn the result into a decision
Report annual air cost alongside acquisition, installation, maintenance, downtime and any change in output. Show a low, central and high case for uncertain operating hours or air cost. A payback calculation is useful only when the incremental investment and comparable annual benefit are stated. Retain the measurement record so the result can be checked after installation.
WILDEN pumps and parts support
For a configuration or spare-parts inquiry, send the complete model code and describe the actual duty. Willee can review the available product information and identify the details needed for a quotation.