Silent Leaks, Resounding Savings: How Acoustic Imaging Is Saving Pennine Healthcare Thousands

Based in the UK, Pennine Healthcare manufactures and distributes a range of products for use in the medical industry. Increasing global demand has resulted in the company employing a 24-hour shift system, with products being shipped to more than 50 countries. 

Pennine has always held product quality in the highest possible regard, after all, there is no room for compromise or imperfections in medical devices where contaminants in production can literally be the difference between life and death. Cleanliness, precision and the highest production standards have always been core values for Pennine Healthcare which resulted in some non-production-related maintenance issues being a secondary priority. An example of this was the monitoring of energy usage and optimising manufacturing costs. 

A baseline of excellence in thermal and acoustic inspections

Enter Baseline RTS, a UK-based condition monitoring consulting company that specialises in supporting companies with their acoustic and thermal inspections. Baseline RTS Founder, Micky Jackson, was able to visit Pennine Healthcare to conduct an air leak survey, not only identifying leaks but also quantifying them using a FLIR Si2 acoustic imaging camera.

Throughout a full-day acoustic inspection, Micky and Pennine Maintenance Technician Joe started their inspection with the bank of 3 Atlas Copco compressors, which had recently been upgraded to operate ‘at demand pressure’ rather than running at maximum pressure charging a pressurised reservoir, turning on and off as much higher pressure ‘stored air’ from the tank is used up throughout the day.

Detecting hidden air leaks to drive down energy costs

After inspecting the compressors, Micky worked through the extrusion feed system, finding hidden leaks that were inaudible to the human ear and yet proved to be a constant drain on energy and costs.

From the extrusion system, the inspection entered the ‘clean-rooms’ which require monitored hand washing, hair nets, beard nets, a change in shoes and specific over-coats before entering, illustrating Pennines uncompromising standards towards product quality. With multiple pneumatic operations throughout these rooms, it was possible to find leaks in all the usual places such as air couplings, elbow joints, and air tools. But then came a complete surprise; not only were there leaks in the usual places but also in the actual sealing equipment.  

The final stop was the facilities maintenance workshop where the compressed air feed was obscured from view, above suspended ceiling tiles where 2 leaks were detected, again silent and undetectable without ultrasonic imaging equipment.

The following day, Baseline RTS sent an acoustic report to the team at Pennine listing leaks which when repaired will represent a conservative estimate of £7,000 per year. Micky commented: “The survey was typical of most manufacturing sites who are typically unable to detect inaudible air leaks without investing in specialist equipment themselves.”

Richard at Pennine explained that he can use this cost saving and data to justify repeat acoustic surveys in the future or even the purchase of an acoustic camera for the Pennine Healthcare facilities maintenance team to stay on top of leak detection themselves. As more and more companies request sustainability reports and actions taken to reduce carbon footprints from their suppliers, this information can also be added to reports as evidence that the company is taking positive steps towards net zero and scope 1 certification. 

Micky explained, “When these leaks are repaired, a follow-up survey would be valuable as it is highly likely that more leaks exist, after all we ran out of time rather not leaks during the survey!”

Pennine Healthcare has already committed to another review in a few month’s time where past experience tells them that more leaks will have developed due to the movement of air lines, and general wear and tear on components.