CONSTANT INNOVATION PET Compressed Air Solutions

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C O N S T A N TI N N O V A T I O NPET Compressed Air Solutions

Take a Different PathSolutions of ChoiceAn era of choice begins. Ingersoll-Rand introduces creativesolutions to the production challenges of PET bottle blowing.Ingersoll-Rand PET Solutions offercustomers not only reliability, efficiencyand productivity, but the lowest life-cyclecost of ownership, as well.For the first time, you can choose between different, highlyadvanced air compression technologies — which now include theoutstanding performance of four-stage centrifugal andreciprocating compressors — to select that which best meets theunique production requirements of your plant.The reasoning is straightforward. To compete successfully in theglobal marketplace, companies like yours must keep productionlines running smoothly and with minimum interruption.Downtime, whether scheduled or unscheduled, is costly.So, with a thorough understanding of the dynamics in today’sstrenuous production environment, Ingersoll-Rand unveilsground-breaking 4-stage centrifugal technology and 4-stagereciprocating technology, for unmatched reliability andperformance. Together with our other highly regardedreciprocating solutions, these superior technologies from a singlesource provider offer the PBM Industry: Lower life-cycle costUnmatched product durabilityAbility to thrive in punishing environmentsEconomical and efficient solutions to maximize productivityNumerous configurations to meet any operational needTake the vital first step in choosing the right solution. CallIngersoll-Rand. Our thoroughly trained staff is ready to help youevaluate your air system to determine your compressed air needs.Ingersoll-Rand has broken the rules!We are the only manufacturer thatoffers PET customers centrifugalcompressor technology. This stateof-the-art compressor offers thehighest reliability of any compressorin its class.2Ingersoll-Rand offers a full range ofsuperior 4-stage compressor technology.What does this mean to our customers?Highest energy efficiency.

Ingersoll-Rand understands thatcompressed air means system not justcompressor. That is why we are the onlymanufacturer in the PET industry thatoffers total care solutions.3

C750State-of-the-Art ReliabilitySeveral years ago we embarked on an ambitious quest toprovide the most reliable air compressor solution availableto the PBM industry. We achieved our goal with theintroduction of the Centac C750. Specifically designed fordemanding PBM applications, the C750 has few movingparts and virtually nothing to wear out. Valve, ring andpacking changes become a thing of the past. Centaccompressors, by design, will run for long intervals — andsince they stay running, you keep producing. Featuring anon-contact compression cycle, the C750 offersunsurpassed air quality, oil-free, with no particles inducedinto the air stream. Experience legendary reliability and thepeace of mind it brings with the new Centac C750 solution.Centac C750 Model C60MX4BENEFITS Simplicity by design — four main rotatingparts Gear-driven main oil pump ensureslubrication during coast down 100% oil-free non-contact compressioncycle, no particles generated during thecompression process Mounted and piped no-loss stylecondensate removal traps standard on allmodels Four-stage from atmosphere design foroptimal efficiency Anti-corrosion protection standard on allinternal passages Ultra compact footprint with no vibrationor unbalanced forces to contain Ingersoll Rand’s advanced CMC microprocessor-based controller monitorsall critical system parameters in real time Low installation cost single point air andwater connections Stainless steel interconnect piping withstandard flange fittings Ambient and parallel valve control logic Intercoolers and aftercoolers designed for6 C approach temperature Standard constant pressure or auto-dualcontrol modes All components constructed in accordancewith World Standards and stamped asapplicable Complete factory load tested package System matched components carefullychosen to ensure superior performance 85 dBA sound level (measured in free fieldcondition with standard ODP motor) On-screen start up and basic maintenanceinstructions simplify 630*Reference Conditions: Inlet Pressure — 1 Bar, Temperature 20 C4PressureBar4242L43904390Dimensions mmW25702570H18801880Weightkg954510000

4Four-Stage AtmosphericNow available withWhen unsurpassed performance and reliability are required, thePETStar-4 line of 4-Stage Reciprocating Air Compressors answers thechallenge. Robustly designed and configured in a horizontally opposedcylinder configuration, the PETStar-4 arrangement virtually eliminatesvibration with a minimal foundation requirement. By utilizing fourstages of compression, the PETStar-4 is capable of providingunsurpassed compressor efficiency. Lower stage compression ratiosreduce the cylinder operating temperatures and extend the life of valves,rings, and packing. To simplify installation, all PETStar-4 units feature aheavy-duty welded steel sub-base and are available with a matching airtreatment component package. Whether you require a compressor forin-line molding or capacity to support a large production operation,there is a PETStar-4 package to meet your needs.EnduraLIFEcomponentsPETStar-4 Model 3300BENEFITS Electrical driven pre-lubrication system Three-step capacity control 0-50-100% Four-stage balanced opposed layouteliminates unwanted vibration Large cast-in water jackets fordimensional stability under extremeconditions Advanced CMC main compressorcontroller with 1,000 event loggingcapability built-in All double acting, heavy-duty class-40 castiron cylinder construction Conservatively designed valves selected toprovide extra long-life IP-55 TEFC, 6-pole main drive motor Sleeve type main and connecting rodbearings Lowest interstage temperatures andpressures Enduralife 16,000 hour rated piston ringsand packing Intecoolers / aftercooler selected foroptimal 9ºC approach temperature All components constructed in accordancewith world standards and stamped asapplicable Anti-corrosion coating on all system airpiping Distance pieces feature two compartmentsensuring lubricant is isolated fromcylinders Non-lubricated 100% oil-free, watercooled design Crankshaft driven main oil pump Star-delta main motor starter Available in Basic or Intermediate packageconfiguration with optional piped andmounted dryer and receiver Available rod drop position wear odelStageskWm3/hPS-4 150042501525PS-4 170043151724PS-4 190043151920PS-4 210043552140PS-4 230044002353PS-4 250044502549PS-4 280045002846PS-4 300045003042PS-4 330045603361*Reference Conditions: Inlet Pressure — 1 Bar, Temperature 20 85685685Dimensions 023300239005

Primary Booster SystemsTotal System FlexibilityLarge bottle production operations often consume great quantities ofhigh-pressure and low-pressure air. For certain customers, who chooseto invest in a modular system, IR can provide a primary compressoraugmented by a booster. An advantage of this configuration is that itallows for independent addition of capacity to each circuit. The primarycompressor can be chosen from a wide range of oil-free rotary orcentrifugal compressor designs, which require minimal maintenance.A two-stage non-lubricated reciprocating compressor servesas the booster.Centac CV2Two-Stage Reciprocating BoosterBENEFITS Multiple stages of compression improveefficiency and extend compressor life bymaintaining lower operating temperatures Over-sizing the primary compressor is anefficient method of providing lowpressure, oil-free air for plant use The primary compressor and balancedopposed booster require a minimumfoundation Centrifugal compressors, with few movingcomponents, require minimummaintenance and replacement parts,significantly reducing maintenance costs System capacity can be addedindependently to each circuit allowing formodular expansion The reciprocating booster, by design,requires significantly less valves than thatof an atmospheric compressor, resulting inlower maintenance costs Standard low pressure dryer allows for dryplant air and eliminates possible freezeups due to high-pressure condensateremoval Primary and booster can be sized tooptimize the plant air system. When anexpansion of low or high pressure air isneeded, additional air can be added inthat circuit All compressors, including boosters,tested at 100% full operating pressureLow pressureplant airHigh pressureairLow pressureair dryerOil-free primaryair compressor6Low pressurereceiverTwo-stage boosterHigh pressurereceiver

3 InlineBalanced Three-Stage AtmosphericTradition is something we take seriously at Ingersoll-Rand, and it isdeveloped in our products through constant refinement. The latestPETStar-3 Inline compressors carry on that rich heritage. Redesignedwith state-of-the-art materials and technologies, PETStars are ruggedunits that offer exceptional value to our customers, based onimproved operating life, low maintenance, and high efficiency. Built forlong life, each package is shipped on a rugged steel sub-base, to beeasily installed on any standard concrete floor. Single point air, waterand electrical connections further aid quick installation. A legend fromthe beginning, and refined over the years, there is a PETStar packageto fit your needs.PETStar-3 Inline Model 630AftercoolerHigh pressureair to systemThree-stage compressorHigh pressurereceiverHigh pressureair dryerBENEFITS Three-stage balanced opposed layoutminimizes foundation requirements All double acting stages (780-1540) Rugged frame design — one-piece castiron construction Non-lubricated, featuring long life (8,000hr) self-lubricating composite wearingcomponents Cylinders constructed with large cast-inwater jackets for dimensional stabilityunder continuous operation Advanced Intellisys SG microprocessorbased controller monitors all criticalsystem parameters in real time Intercoolers/aftercooler selected foroptimal 8 C (15 F) approach temperature All components constructed in accordancewith World Standards and stamped asapplicable All internal components and piping arecorrosion protected for extended life Distance pieces feature two compartmentsensuring the lubricant is isolated from thecylinders All compressor packages load tested at100% operating kWCapacitym3/hPressureBarLDimensions mmWHWeightkgPS-3i 420375425404780198022406140PS-3i 6303110639404780198022406140PS-3i 7103132712404780198022406140PS-3i 7803132778405590221022407250PS-3i 8503150848405590221022407250PS-3i 102032001016405590221022407250PS-3i 1280320012784066002590239014910PS-3i 1540325015454066002590239014910*Reference Conditions: Inlet Pressure — 1 Bar, Temperature 20 C7

3Three-Stage AtmosphericPETStar-3 reciprocating compressors are designed to meet theneeds of customers with small rotary or inline blow moldingequipment. These customers require an economical andefficient solution to maximize productivity. Arranged in aspace-saving package, the PETStar-3 has single point air,water and electrical connections for easy installation. Themachine base is also designed with forklift access forconvenient transport. By utilizing a W configuration, access toall areas is made unobtrusive during maintenance operations.Equally robust in design and construction, the PETStar-3 istruly a cost effective solution.PETStar-3 Model 310BENEFITS Non-lubricated, 100% oil-free Durable stainless steel plate valves Three-stage double-acting compressionW-layout Crankshaft-driven main oil pump Rugged frame design: one-piece cast ironconstruction Full floating, pressure lubricated sleevetype main and connecting rod bearings Stainless steel interconnect piping, withSAE O-ring fittings State-of-the-art self-lubricating compositematerial used for piston, wear, andpacking rings Thermostatic water control valves, andsolenoid operated shut-off valve Distance pieces feature twocompartments, ensuring the lubricant isisolated from the cylinders NEMA4 (IP-54) rated main motor starterand control panel Two-step capacity control, 0%-100% Large cast-in water jackets fordimensional stability under continuousoperation All components constructed in accordancewith World Standards and stamped asapplicable Intercoolers/aftercoolers selected foroptimal 8 C (15 F) approach temperature Single point air, water, and electricalconnections Advanced Intellisys‚ SG microprocessorbased controller monitors all criticalsystem parameters in real pacitym3/hPressureBarLDimensions mmWHWeightkgPS-3 170330170402290183016603270PS-3 210337216402290183016603345PS-3 260345245402290183016603430PS-3 310355287402290183016603510*Reference Conditions: Inlet Pressure — 1 Bar, Temperature 20 C8

Type-30Continuous DutyThe Type-30 compressor is an Ingersoll-Rand legend. Thebasic design has been in service throughout the world formore than 75 years. Now newly redesigned and improvedas a continuous duty unit, the Type-30 is perfectly suitedfor intermittent blowing applications, such as single-stepinjection blow molding or small two-step reheat blowmolding processes. The Type-30 is available in single ordual base plate configurations. Our staff is ready to helpyou select the right unit to fit your needs.Type-30 Model 15T2Type-30 Model 7T2BENEFITS 100% Cast iron construction Air-cooled aftercooler 2 or 3 stages of compression availablewith maximum pressure rating up to 68 bar Fully adjustable pressure switch NEMA rated starter with hour meter Pressure lubricated main andconnection rod bearings Single point air and electrical connections Mounted motor starter Heavy-duty two-stage air inletparticulate filter Centrifugal unloader Low level oil switch Rugged one-piece fabricatedbaseplate Continuous duty reModelStageskWm3/hBarT30 7T2x1037.536.535T30 7T4x523.711.240T30 15T2x1027.539.140T30 15T2x1531552.840T30 15T2x15D325105.740*Reference Conditions: Inlet Pressure — 1 Bar, Temperature 20 CMaxBar3570707070L12501250142014202860Dimensions 4324325239

HPS Series Refrigerated DryerValue-Packed SolutionThe high pressure dryer is a vitally important link in the supply ofclean dry air to the blow molding process. During air compression,the compressor concentrates contaminants in the form of watervapor and airborne particles. These contaminants can damage theinternal components of the molding equipment. Our refrigerationdryers have been specially designed to exceed the requirements ofdemanding PBM applications. As compact space saving units, theyare built to exceed the strict international standard of ISO 8573.1class 4 governing pressure dew-point. The HPS series will providemany years of trouble-free operation.IR Model HPS 3000 System pressure gauge Power on indicator Inlet pressure gauge System operating Suction pressure gauge High evaporation temperature On/off switch Compressor fault alarmBENEFITS Ultra compact, plate style heat exchangersconstructed of 100% stainless steel Integrated filter/separator with cyclonicaction for superior moisture removal Meets ASME, CE, CSA, UL, and CRNcertification Environmentally friendly HFC refrigerantsR134a (HPS 300 – 1000),R-404a (HPS 1250 – 3750) Non-cycling, reliable reciprocating andscroll compressors Auxiliary dryer/compressor interlock toensure dryer is operational beforecompressor loads 3 C stable dew point Integral hot gas bypass valve Electronically programmable solenoiddrain valve Available in both air-cooled or watercooled ter-CooledNominalMAWPDimensions mmModelNm3/hNm3/hkWBarLWHHPS 3005205901.1508109701090HPS 5008609902.0508109701090HPS 750129014802.45011209701090HPS 1000172019803.75011209701090HPS 1250215024705.35011209701090HPS 1750300034607.750127012201270HPS 2000343039509.850127012201520HPS 30005150592014.150127012201520HPS 37506440740016.550127012201520Flow and pressure drop at MAWP (Maximum Allowable Working Pressure) and at 60 Hz, 38 C.38 C inlet and 38 C ambient temperature.Dimensions and weights are for reference only, please refers to the installation, and construction manual for detailed information.MAWP is given at 38 C inlet, and 38 C ambient temperature. Correction factor for 50 Hz operation - .8310Weightkg168172211218268465590710719

40 Bar Filters and StorageHigh Pressure AccessoriesProperly sized storage is crucial to realizing the maximumperformance of your compressed air investment. Often critical inthe operation and reliability of a system, stored compressed airprovides the capacitance necessary for the system to react todemands from the production floor. Additional sufficient storageprovides a buffer to enable the controls from rapid cycling of yourcompressors. Ingersoll-Rand long has recognized the need forproperly sizing the air storage system. Our experts will help you inidentifying your storage requirements. Receivers are available insizes ranging from 120 gallon through 5,000 gallon and withratings of 125, 150, 300, 550 and 725 Maximum AllowableWorking Pressure.Vertical Air ReceiverIngersoll-Rand also offers avariety of high-pressure filtersto meet any requirement.BENEFITS Increased reactance time decreases short cyclingof your compressed air system All components constructed in accordance withWorld Standards and stamped as applicable Provides a pulsation buffer between down streamequipment and the compressed air source Internal corrosion protection to maintain maximumperformance over service lifeSPECIFICATIONSGeneral PurposeHigh cronBarm3/hSizeHPGP 8001HPHE 8000.01611,3601”NPTHPGP 20001HPHE 20000.01613,4001”NPTHPGP 40001HPHE 40000.01486,8003”NPT*Dimensions and weights are for reference only. Please request certified drawings for installation purposes.Dimensions mmLW3801306101001040250Weightkg6116711

Controls SystemsAnticipating Your System Control NeedsWhether it’s local compressor controls or system wide configurations.Ingersoll-Rand has solutions that save. We save in three ways:1Reliability SavingsIR controls will improve youroperations process. Adependable product air systemmeans a dependable productto your customers.2Energy SavingsIR controls reduce wasted airat the compressor and atsystem levels. Controlsreduce air pressure andincrease throttle range toconserve air and energy.3Maintenance SavingsPreventative maintenancefeatures in both compressorand system will help warn usbefore physical symptomsarise.Intellisys SGThe Intellisys SG is IR’s basic microprocessor and is standardon most PetStar models. The easy to read LCD display allowson the fly adjustments to be made quickly and easily. Othercapabilities of this controller include: Interstage temperature and pressure monitoring Real time system diagnostics and troubleshooting Comprehensive data display RS-232 interface capabilities Security protection Retrofits availableIntellisys SGCMC MicrocontrollerThe CMC is the most advanced microcontroller for aircompressors available in the marketplace today. It is standardon all Centac products and optional on the PetStar 4 productline. It utilizes a large graphical screen for viewing largeamounts of data at once. Other features of this state-of-the-artcontroller include:CMC Microcontroller12 LCD membrane touch padDifferent language capabilities for user friendly interfaceReal time system diagnostics and troubleshootingEvent logging for up to 1008 eventsMODBUS protocol with communications cardRS-232 and 422 interface capabilitiesActive security protectionRetrofits available

Intellisys Energy OptimizerThe Intellisys Energy Optimizer is a microprocessor based controller designed tominimize operational pressure. By tightening the control band, excess pressureis eliminated and energy is conserved. The IEO will also determine the precisenumber of compressors required to supply system pressure and floweliminating wasted power. When the compressors are not in demand the IEOshuts them down. Other capabilities include: Large graphical user interface Optional dewpoint monitoring System pressure band control Built-in sequencer for up to eight machines RS-232, 422 interface capabilitiesAir System ControllerIR’s Air System Controller ASC, is a computer-based controller designed tominimize operational pressure. The ASC integrates all your compressed airneeds into one control package. The primary goal of the ASC is to monitor andcontrol your compressed air system and optimize its operation. Features include: Integration of complete compressed air system Energy management through load sharing Remote communications through network monitoring/real time data check Remote notification of equipment alarm or trip status option Report generator with event log and date and time stamp Object oriented graphics and dynamic icons Intranet, internet and LAN capableAir System ManagerThe Air System Manager ASM, is IR’s most powerful computer-based controller.It is designed to incorporate all compressed air equipment, including ancillaryequipment, regardless of make. Based on Wonderware/Intellutions software, aunique solution can be custom configured to meet the needs of the productionenvironment. Additional capabilities include: Integration of complete compressed air system including auxiliary equipmentsuch as dryers, chillers, cooling towers, etc Energy management through load sharing Remote communications through network monitoring/real time data check Remote notification of equipment alarm or trip status option Report generator with event log and date and time stamp Object oriented graphics and dynamic icons Intranet, internet and LAN Custom software applicationsIntellisys Energy OptimizerAir System ControllerAir System Manager13

Audits and AirCare ServiceIngersoll-Rand Audit SolutionsIn the past you asked us to build thebest-engineered most reliable, energyefficient air compressors in the industry.But in today’s global business climate,you need more than great equipment tosurvive and thrive. Increasing value forour customers means we must gobeyond the components of an airsystem and find solutions to theoperating issues every customer faces.The problems associated withoperating a modern compressed airsystem are fairly complex. At the sametime, many companies have cut backthe internal resources dedicated todefining and solving those problems.about taking compressed air, looking atit as your fourth utility, and makingcompressed air as stable andconsistent as your other utilities.That’s where IR Audit Solutions canhelp. Audit Solutions addresses thetotal process of producing compressedair — not just the compressors. It’sYou can’t manage what you don’tmeasure. Knowing what your system isdoing is the first step in reducing costsand improving productivity.The BenefitsFSFEASIBILITY STUDY: Analysis by walkingaroundFAEFFICIENCYEFFICIENCY Interview operations,finance, management Identify potentialopportunities from asupply-side audit or fullsystem auditCustomerNeedsSAPRODUCTIVITYPRODUCTIVITY Differentials, signals andset points managementFS Pressure dropmanagement yieldssignificantenergy savingsRELIABILITYRELIABILITY Air quality managementresults in significantproductivityimprovementsFASASTARTING POINT14SUPPLY-SIDE AUDIT:FULL SYSTEM AUDIT: All audit componentspreviously identified,plus. An exact match ofoptimal demand-siderequirements to minimumcompressed airconsumption

Our Service Pledge to YouIR’s Audit Solutions can give yourplant these critical benefits:Reduce Operating Costs Operating costs can be reduced byup to half of the current costs. Reductions in energy, maintenance,water and rentals will feed yourbottom line.Improve Productivity Stabilize air pressure under allconditions at all points-of-use.Adding compressors isn’t the onlyway to increase pressure at a pointof-use. Eliminate moisture, oil orcontamination problems, whetherthe root cause is the equipment orthe application. Compressed air might be“invisible,” but that doesn’t mean itcan’t be the cause of processproblems when improperly applied.Minimize or Eliminate FutureCapital Expenditures Turning off a compressor orreducing the load can create a backup machine out of your existingcompressors. If your system is onthe brink of expansion, an audit canhelp you squeeze more out of yourexisting system, delaying the needto expand. If the expansion is large,the audit can help you “right-size”the components rather thanoversize the equipment “just incase.” This saves money on bothequipment and installation.Ingersoll-Rand has earned a world-wide reputation for providing the finestcustomer service available from any manufacturer in its field. We recognize that ourcustomers count on the equipment we build and the services we provide to helpkeep their production processes running smoothly and without interruption —essential if they are to stay competitive in today’s business environment.This is a trust that we do not take lightly.Therefore, we pledge to you: Our parts and service network will respond toyour needs 24 hours a day, 365 days a year.We will not let you down. If a problem develops, we will fix it fastand fix it right. We will stand behind the work we perform. No matter where in the world you are located,we will be there for you.AirCareAirCare, an Ingersoll-Rand exclusive, isa responsive and flexible contractmaintenance program custom-designedto provide customers with factoryauthorized scheduled maintenance forincreased system reliability. AirCarehelps eliminate unscheduled downtimeand relieves customers of the costlyinvestment in monitoring equipment,ongoing training and a thoroughknowledge of compressor technology.The AirCare ProgramNo long-term maintenance program ismore comprehensive than AirCare. Thehighlights of the program include: Certified, professional technicianswill perform routine inspections anddiagnostic service Performance will be enhancedthrough exclusive use of genuine IRparts and lubricants All-inclusive fluid analysis programwill comprehensively monitor thelubricant in the compressor to detectproblems at the earliest possibleopportunity Vibration analysis diagnosticspinpoint the need for componentreplacement through monitoring andtrend analysis that predicts theservice life of critical componentsRemote Monitoring An added option to AirCare is IR’sIntelliguard remote monitoringfeature. This 24-hour-a-day, sevendays-a-week, surveillance of the aircompressor installation helps identifypotential problems at an early stageand prevent unexpected repairs.15

Proven Customer Savings.Online solutions: www.air.irco.comMember ofwww.cagi.orgIngersoll-Rand compressors are not designed, intended or approved for breathing air applications. Ingersoll-Rand does not approve specializedequipment for breathing air applications and assumes no responsibility or liability for compressors used for breathing air service.Nothing contained on these pages is intended to extend any warranty or representation, expressed or implied, regarding the product described herein.Any such warranties or other terms and conditions of sale of products shall be in accordance with Ingersoll-Rand’s standard terms and conditions ofsale for such products, which are available upon request.Product improvement is a continuing goal at Ingersoll-Rand. Designs and specifications are subject to change without notice or obligation.Ingersoll-Rand CompanyHeavy Industrial Air Solutions800-B Beaty StreetDavidson, NC 28036Ingersoll-Rand CompanyHeavy Industrial Air SolutionsStrada Provinciale Cassanese 10820060 Vignate, Milano, ItalyIngersoll-Rand CompanyHeavy Industrial Air Solutions11F, Xu Hui Yuan Building1089 Zhong Shan Nan Er RoadShanghai, 200030, China, PRC 02/2005 Ingersoll-Rand CompanyForm 99932170Printed in Europe

compressor can be chosen from a wide range of oil-free rotary or centrifugal compressor designs, which require minimal maintenance. A two-stage non-lubricated reciprocating compressor serves as the booster. BENEFITS Multiple stages of compression improve efficiency and extend compressor life by maintaining lower operating temperatures

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