MANN+HUMMEL, a global leader in filtration systems, faced major operational challenges due to an outdated compressed air system. Frequent malfunctions—over 20 air-related downtime incidents daily—and water contamination of up to 30 gallons per hour were costing the company more than $160,000 annually in lost productivity and maintenance expenses.
“When an air system fails, it doesn’t just stop production—it causes ripples across the supply chain,” said Steven Owens, Senior Manager, Manufacturing Engineering at MANN+HUMMEL. “It delays shipments, raises costs, and impacts our customers.”
Partnering for Change: Pattons and ELGi Step In
To tackle these issues, MANN+HUMMEL partnered with Pattons Inc., a subsidiary of Elgi Equipments Limited, to revamp its compressed air system. Over a 12-week period, Pattons implemented a solution using ELGi’s energy-efficient compressors and dryers. During installation, Pattons provided rental compressors to maintain uninterrupted production, saving MANN+HUMMEL nearly $500,000. The final setup included:
- Five ELGi EG-160 rotary screw compressors (three fixed-speed, two VFD for demand-based output)
- Three ELGi AR-2350 high-performance dryers to eliminate moisture and stabilize pressure
- Airmatics Smart Control System to automate operations and reduce energy consumption
- Airmate Air Receiver wet and dry tanks to regulate moisture levels
Immediate Impact: Plant Efficiency Restored
The overhaul had an immediate and noticeable impact. “It was like we had a brand-new plant,” Owens remarked. “No more air pressure drops, no more moisture issues. For the first time in years, we had consistent, reliable air throughout the facility.” With stabilized production and no maintenance emergencies, operational efficiency surged.
Improved Quality and Product Consistency
In addition to reducing downtime, the new system resolved long-standing quality issues. Moisture damage to tools and seals, as well as fluctuating pressure causing faulty test results, had previously led to product rejections. “After the upgrade, all that stopped. We finally had clean, stable air—and that directly translated to higher product quality,” Owens added.
Clearing a Six-Million-Unit Backlog
Post-COVID, MANN+HUMMEL faced a six-million-unit backlog. With the new system in place, the company leveraged increased uptime and efficiency to clear the delays and meet customer demand.
“For many of our customers, filtration is mission critical,” Owens said. “This upgrade didn’t just help us catch up—it fundamentally transformed how we operate.”
Unlocking Additional Savings with Energy Rebates
Pattons also helped MANN+HUMMEL secure a $300,000 rebate through Duke Energy’s energy efficiency program. This involved verifying compressor performance, calculating energy savings, and conducting heat recovery analysis with a third-party engineering firm.
“We didn’t just accept the standard rebate,” said Trey Carter, Systems Specialist at Pattons. “We dug into the data to maximize savings—and it paid off.”
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