CONFERENCE

Attendees will earn 12 PDH Credits

OPENING SESSION

Opening Day Panel Discussion

The Critical Importance of Industrial Energy & Water Efficiency

Tuesday, October 13, 2026, 11:15 AM – 12:15 PM. Join us for The Opening Session.

PLENARY SESSION

The Future of Manufacturing

Featuring Jake Hall, the Manufacturing Millennial

Wednesday, October 14, 2026, 11:15 AM – 12:15 PM. Join us for The Plenary Session.

Track 1

Session 1: Natural Refrigerants and Heat Pump Energy Savings

Tuesday, October 13, 8-9:15 a.m.

Powering Decarbonization: Next-Generation Heat Pumps Driven by Natural Refrigerants

Mustafa Wahid, Mechanical Design Engineer, Roche Diagnostics

As global regulations phase down synthetic F-gases, natural refrigerants – specifically propane (R-290), carbon dioxide (CO₂ / R-744), and ammonia (R-717) – are redefining energy efficiency in modern heating systems. This presentation explores how deploying natural refrigerant heat pumps bridges the gap between deep decarbonization and lower operational energy costs. Attendees will learn how these three natural working fluids achieve high seasonal performance, replace fossil-fuel heating and future-proof building and industrial operations against rising energy prices and regulatory penalties.

Mustafa Wahid is an award-winning mechanical engineer and technical leader specializing in master infrastructure utilities planning, capital leadership and sustainable design across the Americas region. Armed with deep expertise in natural refrigerants and aligning global utility operations with zero-CO₂ initiatives, he serves as the Regional SME for Roche Diagnostics, overseeing large-scale CapEx projects. Backed by over a decade of experience (Roche, Baxter, Exelon) and key credentials like C.E.M., C.E.A. and C.B.C.P., Wahid seamlessly bridges the gap between technical rigor and global corporate strategy.

Making Heat Pumps Deliver: Design Strategies That Maximize Energy Savings, Reliability and Performance

Rob Tanner, Director of Marketing for Applied Equipment, Johnson Controls

Heat pumps are becoming an essential technology for reducing energy consumption and supporting building decarbonization initiatives. Achieving the expected results requires more than selecting the right equipment. This presentation explores the system-level design decisions that have the greatest impact on performance, including operating temperatures, hydronic system design, controls integration, thermal storage and optimization strategies. Attendees will learn how these factors influence energy savings, reliability and long-term operational outcomes. Through real project examples and practical lessons learned, this session will provide a framework for successfully implementing hydronic heat pump systems in commercial, institutional and industrial facilities.

Rob Tanner has more than 30 years of experience in the sale, application, design, installation, service and marketing of commercial HVAC products and technologies. Before joining Johnson Controls, Tanner was an MEP consulting engineer and co-owner of a design-build mechanical contracting company. He received his B.S. in mechanical engineering and M.S. in education and organizational development from the Pennsylvania State University.

Session 2: Optimizing Chiller Plants and Free Cooling Systems

Tuesday, October 13, 9:30-11 a.m.

Energy-Efficient Strategies for the Design and Operation of Chilled Water Systems for Comfort Cooling

Hemant Tiwari, Sr Energy Engineer, St. Jude Children’s Research Hospital

Cooling accounts for 14% (170 billion kWh) of total electricity consumption in commercial buildings. For manufacturing facilities, it’s 8% (76 billion kWh). Once commissioned, chiller plant and equipment stay operational for decades – presenting significant energy cost over its useful life. A single percent decrease in annual energy consumption will reduce the total electric cost burden for U.S. facilities by at least a million dollars annually, while reducing CO₂ emissions by over 300k metric tons. This presentation provides an overview of optimization strategies starting at chilled water system design and equipment selection then moving on to established real-life, low-cost and no-cost optimization strategies during plant life cycle.

Hemant Tiwari specializes in identifying, developing and implementing energy conservation measures, with a deep understanding of utility and government energy efficiency programs and regulations, particularly in compliance with New York City’s Energy Efficiency Local Laws. Tiwari has worked across various sectors, including healthcare and government, managing projects from scoping to final inspection. He is well-versed in key standards such as ASHRAE 62.1, 90.1 and 170, and holds the Project Management Institute’s Project Management Professional credential and Association of Energy Engineers’ Certified Energy Manager (CEM), Certified Building Commissioning Professional (CBCP) and Certified Measurement and Verification Professional (CMVP) certifications.

Free Cooling with Cooling Towers: Winter Operating Best Practices

Jim Nonnenmann, President and Principal Mechanical Engineer, PRVN Consultants

The presentation will review key considerations for the design, installation/construction and commissioning of packaged and field-erected cooling towers and the impact to these systems when free cooling and other winter operation scenarios are employed. You will learn the key factors in sizing cooling towers through real-world lessons learned and challenges for these installations as well as freeze prevention measures during winter operation.

Jim Nonnenmann has over 27 years of professional experience including study, design, construction and commissioning services for district energy systems (central heating and cooling, combined heat and power, etc.), utility distribution systems, power systems and supporting facility mechanical systems. He has a BS in in mechanical engineering from the University of Illinois at Urbana-Champaign. Nonnenmann is a registered professional engineer in 13 states and is NCEES registered.

Session 3: Integrated Energy Efficiency and Decarbonization Case Study

Wednesday, October 14, 8-9:15 a.m.

Unlocking Synergies: Modernization, Electrification and the Hidden Value of Existing Assets

John Troyer, Regional Facilities Manager, Schneider Electric, and Edward Kiser, PE, Director of Engineering, World Energy Innovations

Many facilities pursue energy efficiency as a sustainability objective, but for industrial operations, efficiency is fundamentally tied to cost control, reliability and overall performance. This session explores how we transitioned from disconnected building systems into integrated energy management strategies that coordinate HVAC, compressed air, lighting, controls and waste heat recovery.

This presentation outlines practical approaches to uncovering and implementing opportunities with minimal disruption. Key measures include deploying triplicate sensors for accurate, resilient data inputs; automating building pressure controls to reduce winter infiltration and stabilize airflow; capturing and reusing waste heat from industrial equipment to offset building heating loads; and leveraging smart lighting occupancy data to dynamically optimize HVAC and compressed air runtimes. Attendees will learn how integrating these systems creates improvements in reliability, occupant comfort and energy performance while lowering operating costs and advancing electrification and modernization strategies.

John Troyer, CEM, CPEnMS, CDMS, CPV-Industrial, helps lead energy strategy with a focus on practical, scalable solutions improving efficiency, reliability and operational performance. His work includes integrating building systems, modernizing controls, electrification and deploying data-driven automation across HVAC, compressed air and lighting platforms. Troyer’s experience spans plant operations, use of energy modeling and metering strategy, with a focus on aligning energy performance.

With more than two decades at WEI, Ed Kiser, PE, has been directly involved in the assessment, design and implementation of high-reliability mechanical systems, including campus-scale steam-to-hot-water conversions, central utility plant optimization, modular combined heat and power, heat recovery and advanced control strategies. His work is grounded in a deep understanding of how facilities actually operate and how design decisions perform once systems are in service. Kiser holds a B.S. in aerospace engineering from the University of Michigan and is an active member of ASHRAE and the Association of Energy Engineers.

Session 4: Intermittent Demand Control Strategies: From Multiple VSD Compressors to Solutions for Big Air Events

Wednesday, October 14, 9:30-11 a.m.

Multiple Variable Speed Drive Compressed Air Controls Automation

Tim Dugan, President, Compression Engineering Corporation

How can you integrate large sets of air compressors that include VFD compressors? This presentation will explore rotary screw air compressors, variable speed controls with compressors, controls problems with VFD compressors and control algorithms to optimize VFD compressor utilization. A case study will be used to demonstrate principles.

Tim Dugan, PE, has 25 years of independent industrial compressed air systems consulting experience and 13 years of OEM design, and is known for rigorous system modeling, developing the basis for system design and energy savings economics, as well as for M&V. He can integrate all aspects of a complex compressed air project, including concept, controls, monitoring, mechanical systems and commissioning. Dugan’s engineering consulting firm is 100% independent from air compressor OEMs.

“We Need More Air Pressure,” What Now?

Tom Taranto, Owner, Data Power Services

This presentation will discuss various causes of low pressure: Air Gulpers (aka high-volume intermittent demands), undersized distribution piping and restrictive air connection at the last “dirty 30.” Discover how to identify the cause. Is the entire compressed air system pressure low? Is only a portion of the system being impacted? Is the problem in a very small area, or maybe a single production line or machine? Learn steps you can take to find the root cause and various solutions to consider.

Tom Taranto is an independent compressed air system professional with more than 40 years of experience providing services to industrial clients, utilities, and energy agencies. His work involves compressed air system design, air compressor application and performance of related compressed air system components. Taranto conducts compressed air system assessments, equipment testing and compressed air system training throughout the world.

Session 5: Designing High‑Performance Compressed Air Systems

Thursday, October 15, 8-10 a.m.

Compressed Air is the Byproduct: A Thermodynamic Analysis

Bryan Jensen, Engineering, Independent

“Heat Recovery” in our industry is a bit of an unfortunate phrase, as its use implies the primary thing being done in any air compressor room is generating compressed air. Start thinking like a utility power provider and see how best to begin turning your air compressor room into a cogeneration plant by adding one critical component to every lubricated rotary screw air compressor you purchase, starting today.

Bryan A. Jensen is a mechanical engineer with over 24 years of application experience in a wide variety of industrial manufacturing processes focused in the vacuum and compressed air and gas industries. He grew up in Alaska, trained in the Midwest and started his career as a NASA materials research engineer in the Deep South before returning to the Pacific Northwest. Jensen owns and operates an independent thermodynamics laboratory offering performance testing of compressed air and vacuum machinery with integrative component prototyping and technical marketing content, writing and training services.

The Hidden kWh Cost of Compressed Air: Quantifying Downtime, Low Pressure and Air Quality Issues Driving Production Loss

Peter Vinck, Founder, President and Principal System Engineering Consultant

Compressed air auditing has long focused on the kWh consumed by air compressors, but the larger energy story is the kWh burned everywhere else when the compressed air system fails – the lights, HVAC and production equipment that keep running during idle time, plus the extra machine hours and conditioning needed to remake scrap and catch up on lost output.

This session presents a vendor-neutral methodology for quantifying these hidden kWh losses across three failure modes: hard downtime events, low-pressure excursions pushing product out of tolerance and undetected air quality issues – moisture, oil carryover and particulate – that contaminate processes without triggering an alarm.

The total kWh impact of these failures routinely dwarfs the energy savings opportunity at the air compressor itself, yet almost no audit methodology captures it. Drawing on field examples from manufacturing and municipal sites, attendees will leave with a defensible calculation framework and a template for re-framing compressed air conversations with operations and finance leadership.

Peter Vinck has spent 16 years at Inflow Corp independently designing, data logging and optimizing industrial compressed air systems. Before launching Inflow, he served as an Energy Efficiency Engineer at a major electric utility, a system designer and auditor for a top equipment vendor and began his career as an application and sales engineer for a leading compressed air manufacturer.

Practical Habits to go from Initial Concept to Final Commissioning

Gil Rangel, Senior Project Manager, ADG Concepts

You envisioned an optimized compressed air system, collaborated on a complex engineering solution and secured equipment. Now, how do you successfully bring that design to life without losing pressure along the way? Between the initial design and the final pressure test of implementation, there’s a massive gap where compressed air systems either run efficiently or leak money. Grounded in the principle that all things are created twice – first in the mind and then in reality – this presentation helps bridge that gap.  We will look at practical steps to help your compressed air project, ranging from large new build to adding new process equipment to optimizing an existing system, jump from design to reality.

Gil Rangel plays a crucial role in building teams, safety oversight and customer relations at ADG Concepts. A Green B Trimble Tech alum, with a focus in construction management, Rangel began his career as a welder in the oil and gas industry. At ADG, he is known for growing and enhancing team skills, managing large-scale projects and demonstrating a deep commitment to both professional excellence and personal growth within the industry.

Session 6: Utility Incentives, M&V and Demand‑Side Optimization

Thursday, October 15, 10:15 a.m.-12 p.m

Boosting Compressed Air Performance Through Utility Incentive Programs

Billy Alston, Project Engineer, TRC

This presentation gives facilities a cost‑effective pathway to tackle system inefficiencies and accelerate energy‑saving projects. These programs often help fund engineering studies, leak detection and repair, air compressor and control upgrades and system‑wide optimization efforts that strengthen reliability and reduce energy intensity. By taking advantage of available incentives, plants can move forward with data‑driven improvements such as pressure optimization, demand‑side reductions and advanced control strategies delivering measurable results. The outcome is a more efficient, dependable compressed air system that lowers energy use, reduces maintenance demands and drives long‑term operational savings.

Billy Alston is a Mechanical Engineer with an M.S. in mechanical engineering, specializing in the performance analysis and optimization of industrial compressed air systems. His technical work includes air compressor evaluation, system‑level diagnostics, leak mitigation strategies and data‑driven energy performance assessments. Alston supports TVA EnergyRight by conducting engineering reviews and guiding industrial facilities in implementing high‑efficiency compressed air solutions that improve reliability and reduce energy consumption.

Mastering M&V: Safeguarding ROI and System Performance

Karthik Radhakrishnan, Energy Engineer, Energy Sciences

Measurement & Verification (M&V) serves as the essential technical bridge between engineering execution and financial certainty. By establishing a rigorous, data-driven baseline and comparing it against post-retrofit energy consumption, M&V provides a defensible framework for quantifying true performance of industrial systems.

This presentation will outline established M&V protocols and their practical application across diverse commercial and industrial facilities. It’ll explore technical best practices for high-quality data collection and baseline adjustments, alongside the common analytical pitfalls that can artificially inflate or distort reported savings. By verifying performance methodically, M&V empowers organizations to safeguard their targeted ROI by providing the insights necessary to make informed data-driven investment decisions. Attendees will leave with actionable strategies to implement rigorous M&V frameworks that ensure technical compliance while maximizing economic yield.

Karthik Radhakrishnan, CEM, is a passionate Mechanical Engineer, focused on efficiency improvement and energy savings in mechanical systems. He has over nine years of experience working in energy industry on mechanical equipment design, energy modelling, ASHRAE-level audits and M&V. Radhakrishnan has a master’s degree in energy systems management from Northeastern University, Boston, MA, and extensive experience in working for utility programs focused on commercial and industrial systems.

Stop Making Compressed Air Hold Steel Parts

Nasr Alkadi, Strategic Consultant, Energy and Sustainability, CLEAResult

Compressed air is one of the most expensive utilities in manufacturing, yet it is often used for end-use functions that can be performed more efficiently with mechanical or electromechanical alternatives. This presentation shares a practical case study from an automotive-style metal-handling operation where vacuum cups and venturi devices were replaced with spring-return magnetic pickups for handling ferrous steel parts. The retrofit shifted compressed air from a continuous holding function to a short, low-pressure release function, reducing pneumatic demand while improving the plant’s ability to manage compressed air at the source.

Attendees will learn how the project was evaluated, how the magnetic pickup retrofit was integrated into existing tooling, how savings were estimated and verified and why the first implementation phase achieved a measured plant-wide compressed air reduction of 800 cfm, with 436 cfm attributed to the magnetic pickup conversion. The session will also discuss practical screening criteria, risks, maintenance considerations and how plant engineers can replicate this type of demand-side compressed air opportunity in other metal-handling operations.

Nasr Alkadi, Ph.D., CEM, CDSM, CSRM, is an energy and sustainability professional with more than 20 years of experience in industrial energy management, compressed air systems, decarbonization, measurement and verification and strategic energy management. His background includes automotive manufacturing, DOE national laboratory research, utility energy program delivery and practical implementation of energy efficiency projects that connect plant-floor reliability with measurable cost and emissions reduction. He has authored or co-authored more than 20 technical publications and is a named inventor on seven patents covering industrial energy analytics, remote inspection, sensing, emissions monitoring, air-fuel ratio regulation and related energy technologies.

Track 2
Session 1 & 2: CAGI EDUCATION SEMINAR – Compressed Air Efficiency, Auditing Practices and Certification

Tuesday, October 13, 8-10:30 a.m.

Case Study #1: Station Centralization and Modernization and Case Study #2: On-site Nitrogen Generation

Neil Mehltretter, Technical Director, Kaeser Compressors

When a cement plant needed to improve its compressed air station, instead of simply requesting quotes for new equipment, it conducted a comprehensive compressed air audit. The audit focused on the supply side of the system consisting of 10 stationary air compressors and two portable air compressors scattered across eight different locations throughout the facility. This presentation will review the audit findings and detail the station improvements.

Providing on-site nitrogen generation is a growing trend for many manufacturing plants, but it depends on the purity and scale of the project. This case study will review the overall station design and ROI for one such system.

As Technical Director, Neil Mehltretter oversees Kaeser’s Technical Department with responsibilities including product management, system design and more. An authority on compressed air assessments, Mehltretter has conducted and supervised thousands of industrial compressed air studies, helping users achieve significant energy savings and operational improvements. In addition to his Bachelor’s Degree in chemical engineering from the University of Florida, Mehltretter is AIRMaster+ certified, has completed the DOE Compressed Air Challenge I and II, is a Certified Energy Manager (CEM®), is a CAGI Certified Compressed Air System Specialist and is currently the CAGI System Assessment Section Chair.

Case Studies on Savings and Efficiency Concepts 

Justin Russell, Strategic Assessment Engineer, Ingersoll Rand

This presentation will cover two case studies examining real-world compressed air system challenges by defining the problem, identifying root causes, evaluating potential solutions and reviewing implementation results.
The first case study addresses a system that could not maintain pressure during periods of high demand. While the air compressors were initially suspected, the investigation revealed a desiccant air dryer had become a bottleneck, restricting airflow and affecting overall system performance.

The second case study focuses on issues uncovered during the installation and verification of audit equipment. Although compressed air equipment is often assumed to be operating correctly, problems with inlet valves were identified during signal validation. This example demonstrates the importance of incorporating checks and balances into system assessments to ensure data integrity and achieve reliable outcomes for customers.

Justin Russell earned a bachelor’s degree in mechanical engineering technology and management from Ferris State University. With over two decades of experience in compressed air systems, Russell began his career shortly after being discharged from the United States Marine Corps. He has held various positions, starting as a Technical Service Representative and progressing to Compressed Air Assessor.

Common Auditor Pitfalls and Errors in Compressed Air Systems

Mark Krisa, Global Portfolio Manager, Ingersoll Rand

Compressed air audits can identify significant opportunities for improved efficiency, reliability and cost savings, but only when the system is evaluated holistically. This presentation will highlight common audit pitfalls, including insufficient data collection, focusing on individual components instead of system interactions, overlooking demand-side issues and misinterpreting pressure, controls and leak-related losses. Attendees will gain practical insights to help ensure audits deliver accurate findings and meaningful recommendations.

Mark Krisa has worked in the compressed air industry for over 30 years and his diverse experience in the industry ranges from air compressor service technician through engineering, compressed air system auditor and product management. He has a degree in engineering science from the University of Western Ontario in Canada. Kris has authored several papers and is a project member with CAGI, ISO and CSA.

CAGI Certification Personnel Programs: CCASS & CCASA

Chad Larrabee, Technical Editor, Compressed Air & Gas Institute

The Compressed Air & Gas Institute continues to advance workforce excellence in the compressed air industry through its growing suite of professional certification programs. This presentation will provide an in depth overview of the Compressed Air System Specialist (CCASS) Personnel Certification Program, which validates the knowledge and competencies required to support the proper installation, operation and maintenance of compressed air systems.

Building on the success of the CCASS program, CAGI has now launched the Compressed Air System Assessor (CCASA) Personnel Certification Program, designed to establish a nationally recognized standard for professionals who conduct system assessments, identify efficiency opportunities and recommend performance improvements. Attendees will learn the purpose, structure and eligibility requirements of both certifications, how they support industry best practices and the value they bring to end users, distributors, service providers and energy efficiency programs.

Chad Larrabee is a widely recognized expert in the compressed air industry. His career spans more than 30 years with Ingersoll Rand, where he held a variety of technical and leadership roles. Larrabee now provides industry consulting services through his company, Profundity, and continues to support the compressed air community through his technical expertise, training and industry contributions.

Track 2
Session 3: Compressed Air is a Food Ingredient – Safety First Specifications

Wednesday, October 14, 8-9:15 a.m.

Compressed Air is a Food Ingredient – Safety First Specifications

Phil Kruger, Vice President, Harris Equipment and Roderick Smith, Publisher, Best Practices Magazines & EXPO

Compressed air is an often forgotten ingredient in the food, beverage and pharmaceutical drug products we all enjoy. It comes into direct contact during the manufacturing process and indirect contact through packaging products. Compressed air can be pure when properly treated and monitored. It can also pose a significant risk to consumer safety if not purified of the potential moisture, oil, particulates and harmful bacteria it can bring.

The two presenters have a combined 60+ years’ experience with compressed air quality and continue to observe potentially hazardous compressed air contacting products meant for human and pet consumption. This presentation targets food, beverage and drug manufacturing personnel involved with production Quality, Risk, Reliability and even Legal. It will provide guidance for their plants, and to their packaging vendors, on quantifying the risk, identifying high-risk locations and techniques to ensure compressed air quality is verified – as is done with all other ingredients.

With 26 years of experience in the compressed air industry, Phil Kruger has established himself as a leader in compressed air solutions for the food manufacturing industry. Leading Harris Equipment in Chicago, he has helped bring greater awareness of SQF requirements and compressed air quality considerations to food manufacturers throughout the Chicagoland area. His expertise extends beyond the region, having traveled throughout the United States to train food manufacturers on SQF requirements, compressed air quality and compliance considerations, and his experience includes ISO 8573-1 compressed air quality standards, food-industry supply chain requirements, system design and compliance guidelines.

Roderick “Rod” Muñoz Smith is the Co-Founder of Smith Onandia Communications, LLC. He is the Publisher of Compressed Air Best Practices Magazine and the producer of the annual Best Practices EXPO & Conference. Launched in 2006, this media firm has become “The Global Resource for Efficient & Reliable Facility Utilities.” Our mission is to provide industrial and commercial owners of compressed air, vacuum and chilled water/fluid systems,  with “Best Practice” content and expert guidance. These facility utilities have a significant impact on facility productivity, profitability, product quality and energy/water consumption – accounting for 10 to 40 percent of their total energy consumption. Based in Barcelona, Dusseldorf, Mobile and now Pittsburgh, Smith worked as an executive in the compressed air industry (Quincy Compressor, Hankison International), from 1992 to 2006, and is considered a Subject Matter Expert on compressed air purification and quality.

Session 4: Sustained Energy Reduction Through Operational Discipline and Energy Management

Wednesday, October 14, 9:30-11 a.m.

Operational Discipline as a Driver of Sustained Energy Reduction

Jose Luis Sarmiento Escalante, Facilities and Maintenance Engineer II, John Deere Paton

This presentation shares a practical case study on reducing energy consumption through operational discipline and system optimization. It highlights strategies applied to compressed air and utility systems, focusing on scheduling and accountability. It will demonstrate measurable results achieved with minimal capital investment. Attendees will learn how simple, repeatable practices can drive sustained improvements and how the approach can be replicated across similar manufacturing environments.

Jose Sarmiento Escalante is a Facilities/Maintenance Engineer based in Paton, IA, where he leads capital projects, energy reduction initiatives and site-wide reliability and safety improvements. He is a Colombian Army veteran with a background in civil engineering and an MBA, currently pursuing a Master of Engineering in civil engineering and his Professional Engineer license. Sarmiento Escalante’s work emphasizes practical, data-driven solutions delivering measurable results and operational excellence.

TBD

Brad Runda, Industrial Energy Advisor, ICF (under contract to Oak Ridge National Lab and U.S. Department of Energy)

Brad Runda is an experienced Energy Manager. He built corporate energy management programs at Saint-Gobain North America, Amcor Rigid Packaging and Southwire, and was the global energy director at Koch Industries.

Session 5: Real‑World Compressed Air Reliability and Maintenance Lessons

Thursday, October 15, 8-10 a.m.

The Compressor Room Detective: Uncovering Clues to Improve Reliability, Performance and Efficiency

Sal Calvo, Co-Founder, Compressed Air USA

Compressed air systems leave clues about their health and performance every day, but many are overlooked during routine maintenance. This presentation will discuss how maintenance and reliability professionals can become “compressor room detectives” by asking the right questions and analyzing key operating data before problems occur. Topics will include compressor and dryer operation, controller communication, run-hour balance, system pressure, dew point trends and changes in plant production that can impact system performance. Attendees will learn how a few simple observations and conversations with plant personnel can reveal reliability issues, prevent unexpected downtime and improve overall system efficiency.

Sal Calvo is a compressed air professional with extensive experience in air compressor maintenance, troubleshooting, reliability and system optimization. Throughout his career, he has worked closely with industrial customers to diagnose performance issues, improve equipment reliability and maximize the efficiency of compressed air systems. His practical, field-based approach focuses on combining maintenance best practices with real-world operating data to uncover opportunities that are often hidden in plain sight.

Seven Years in an Air Compressor Room: Lessons Learned

William Orndorff, Engineer, Kiriu USA

This narrative style presentation details one organization’s journey from using outside vendors for all aspects of a compressed air system to performing nearly all work in house. This presentation is for individuals looking to lower operating costs for their compressed air system. Seven years of observed case studies will be used throughout. Topics covered include preventive maintenance, repairs, understanding electrical costs for your facility’s air production, measuring the relative output of your air compressor and steps for lowering electrical costs for air production.

William Orndorff has spent nearly 10 years working on compressed air systems at Kiriu USA, a Tier 1 automotive supplier manufacturing brake discs, rotors and drums. He is a graduate of Western Kentucky University with a triple major in physics, chemistry and mechanical engineering.

Preventing Oil Carryover and Air Compressor Damage in High-Demand Bubbling Applications Using Sonic Flow Limitation

Mustafa Uslu, GM, Revindus and Louis Masse, P.Eng., CCASS, Engineering Supervisor, Quebec & Atlantic, Comairco

A large-scale bubbling application operating eight oil-injected air compressors simultaneously at a total demand exceeding 1,200 kW experienced severe pressure instability during peak consumption periods. When system pressure dropped below 90 psig (6 barg), excessive airflow caused oil carryover from the compressor sump into the process line, creating a serious risk of compressor damage due to oil starvation.

This presentation explains the physical mechanism behind the problem, including air compressor operating behavior under low-pressure/high-flow conditions, and the challenges of balancing multiple compressors in parallel operation. It will explain how sonic nozzles were engineered and implemented to limit maximum flow demand per compressor, stabilizing operation near 100 psig (7 barg) while preventing catastrophic oil migration. Attendees will gain practical insight into compressor air-oil separation mechanisms, choked-flow applications, system protection strategies and real-world compressed air reliability engineering.

Mustafa Uslu is a Mechanical Engineer (M.Sc.) and a specialist focused on compressed air systems, flow control technologies, industrial filtration and turnkey test equipment. He leads an engineering and manufacturing company involving pneumatic systems, pressure control, gas handling and custom industrial machinery for demanding process applications. His work combines practical field problem-solving with in-house design and fabrication capabilities, including CNC machining, sheet metal manufacturing and automated system integration.

Louis Masse, P.Eng., CCASS, started his career in the compressed air industry in 2018 as a Project Manager, and has been a supervisor since 2023. He holds an engineering degree from Polytechnique Montréal and is a Certified Compressed Air System Specialist.

Session 6: Cooling Challenges and Practical Solutions in Plant Operations

Thursday, October 15, 10:15 a.m.-12 p.m.

Efficiency Design in Low Delta T Systems

Clayton Penhallegon, Principal, Integrated Services Group

Many process cooling applications benefit from tight temperature control, which often means the system sees half or less of the nominal supply – return temperature difference common in typical HVAC design standards.  Shoe-horning standard equipment and system designs into these cases frequently means trade-offs in efficiency and/or supply temperature stability.  This session will review the conditions present in these cases, as well as system design and control techniques for realizing efficient operation with superior temperature control.

Clayton Penhallegon has worked for nearly 30 years with various industries including plastics, paper, wood products, metal containers, textiles and others, performing a broad range of activities spanning efficiency measure identification, capital appropriation assistance, system design and project implementation oversight, controls integration and start-up, and utility rebate documentation and verification. He holds a Bachelor of mechanical engineering from Georgia Tech, an MBA from Georgia State University and is a registered PE in Georgia.

Process Cooling Maintenance for Efficiency and Reliability in Plastics

Tom Thompson, Manufacturers Sales Representative, Efficient Plastics Solutions

This presentation will cover the type of maintenance that needs to be done across the different technologies in process cooling for plastics processing. It’ll explore how this will aid in not only the reliability of the system, but also the day-to-day efficiency of the system.

Tom Thompson is the Owner of Efficient Plastics Solutions. He has 41 years of experience in the plastics industry in maintenance, project engineering, field service and technical sales. His career has been focused on uptime and efficiency.

Results of Neglecting Maintenance

Richard Francis, Sales Manager, CM Towers

This presentation consists of case studies demonstrating how important it is to have a comprehensive preventative maintenance program in place and, at a minimum, have professionals get eyes on the cooling towers at least once a year. These two cases show extreme neglect that occurred in very unsafe operating conditions, potentially jeopardizing the health of others and, on a lesser but also important note, operating extremely inefficiently, wasting energy and long-term life of components.

Richard Francis has been employed by CM Towers since 1986, serving multiple positions over 40 years. In his current position for the last five years, he has been in charge of sales, driving the business forward and creating new opportunities. Francis has been involved with the Cooling Technology Institute since 2005, serving on many committees that create and modify best practices for operation, safety and optimal performance of cooling towers.