In 2021, PPG Ltd made a significant multi-million-euro investment in a new manufacturing facility located in Shannon, Co. Clare. The facility was established on the former site of the AVARA Pharmaceuticals plant, which ceased operations in early 2019.
As operations ramped up, PPG retained the existing compressed air system originally installed for AVARA. However, it soon became evident that the production of phosphorescent materials—used in PPG’s LED display and lighting applications—required considerably less compressed air than the inherited system was designed to provide. In short, the compressed air system was oversized for its new purpose. Compounding the issue, parts of the original system, installed as early as 2006, had since been outclassed by modern, more efficient alternatives.
Project Objectives
Jamie McMahon, Facilities Engineer at PPG, initiated a project with the goal of optimising the compressed air system. The Project scope focused on three key areas:
- Creating System Redundancy
- Future-proofing Reliability
- Improving Operational Efficiency
System Evaluation & Findings
The evaluation revealed the following critical insights:
- The oldest 75 kW air compressor, installed in 2006, was starting to experience reliability issues.
- The energy efficiency of the 75 kW unit was poor compared to current compressor models.
- The unit was significantly oversized for the plant’s actual compressed air demand.
- The existing heatless desiccant air dryer, also installed in 2006, was far less efficient than modern heat-regenerative dryers available from Ingersoll Rand.
These findings clearly justified an upgrade.
The Upgrade
In 2024, O’Neill Industrial supplied and commissioned a new, energy-efficient compressed air system. The upgrade included:
- Nirvana IRN 37K-OF VSD Oil-Free Air Compressor
- D500IB-A Heat-Regenerative Desiccant Air Dryer
- Advanced Filtration System
This new system delivers ISO 8573.1 Class 1.2.1 air quality, aligning with best-in-class standards for compressed air purity.
The Results: Efficiency Realised
Eight months post-installation, the results have been outstanding—significant energy savings and a reliable system fit for future plant needs.
Step Change in Electrical Consumption from Day 1
Energy Savings (Measured Results)
| Parameter | Value | Unit |
| Baseline Period Average Weekly Demand | 6,143 | kWh |
| Reporting Period Average Weekly Demand | 4,478 | kWh |
| Weekly Reduction in Electricity Consumption | 1,665 | kWh |
| Percentage Energy Savings | 27% | – |
| Annualised Energy Saving | 86,564 | kWh |
| Annual CO₂ Emissions Offset | 22 | tCO₂ |
| Annualised Cost Saving | €22,247 | – |
| Potential EEOS Credits | €6,059 | – |
Image caption: The New Heat Regenerative Ingersoll Rand D500IB-A Desiccant Air Dryer
Final Thoughts
“Jamie and the team at PPG have demonstrated that the status quo can be challenged. Through data-driven analysis and effective project management, they achieved tangible energy savings and improved system reliability. A textbook example of engineering-led sustainability.”
Austin O’Neill, O’Neill Industrial
“O’Neill Industrial has an established performance history at the PPG Shannon facility, beginning with the successful commissioning of the site’s first Ingersoll Rand compressed air system in the 1980s. I would have no hesitation in recommending them to anyone looking for a reliable partner for Compressed air Equipment and service. Our experience working with O’Neill Industrial on this latest project has been excellent.” Jamie McMahon, PPG
