MANN+HUMMEL, a global player in filtration systems serving industries such as automotive, agriculture, construction, energy, and food and beverage, faced significant operational setbacks due to an aging 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,” explained Steven Owens, Senior Manager, Manufacturing Engineering at MANN+HUMMEL. “It delays shipments, raises costs, and impacts our customers,” he added.
Partnering for Change: Pattons and ELGi Step In
To address the issue, MANN+HUMMEL partnered with Pattons Inc., a U.S. subsidiary of Elgi Equipments Limited, to completely overhaul its compressed air system. Pattons tailored a solution built around ELGi’s energy-efficient compressors and dryers, implementing the system over a 12-week period.
During installation, Pattons provided rental compressors that allowed 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 ensure stable pressure
- Airmatics Smart Control System to automate operations and reduce energy usage
- Airmate Air Receiver wet and dry tanks to maintain optimal moisture levels
Immediate, Plant-Wide Impact
The results were felt instantly. “It was like we had a brand-new plant,” Owens said. “No more air pressure drops, no more moisture issues. For the first time in years, we had consistent, reliable air throughout the facility. Everything just worked,” he added.
With consistent airflow, production stabilized and maintenance emergencies disappeared. Teams no longer scrambled to troubleshoot daily malfunctions, and operational efficiency skyrocketed.
Quality Rebounds with Stable Air Supply
Beyond reducing downtime, the improved system also resolved longstanding quality issues. Previously, moisture infiltration damaged tools and seals, and fluctuating pressure caused faulty test results—leading to product rejections and increased complaints.
“We had clogged systems, defective filters, and inconsistent product assembly,” Owens noted. “After the upgrade, all that stopped. We finally had clean, stable air—and that directly translated to higher product quality.”
Clearing a Six-Million-Unit Backlog
The new system’s impact was especially significant post-COVID. Facing a production backlog of six million units, MANN+HUMMEL leveraged its increased uptime and efficiency to rapidly clear delays and meet demand.
“For many of our customers, filtration is mission critical,” said Owens. “Delays can affect entire industries. This upgrade didn’t just help us catch up—it fundamentally transformed how we operate,” Owens added.
Unlocking Additional Savings with Energy Rebates
Pattons also guided MANN+HUMMEL through Duke Energy’s rebate program, helping secure a $300,000 rebate. The process included verifying compressor performance, calculating energy savings, and conducting heat recovery analysis in collaboration 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,” he added.
