CONFERENCE TRACK 1

Earn 12 PDH Credits

Tuesday, October 21, 08:00 – 10:00 AM

Session #1: CAGI Education Seminar – Case Studies in Maximizing Compressed Air Efficiency

Chair: Steve Briscoe, Senior Director, Hitachi Air Centers – North America

Through real-world case studies and practical examples, CAGI’s educational seminar will illustrate the measurable energy savings, environmental and safety benefits that can be achieved.  From system design and component selection to maintenance strategies and energy audits, attendees will gain actional insights to enhance energy efficiency and safety in their own facilities.

Speaker #1: Solving Leaks and Moisture Issues in Industrial Plant Compressed Air Systems

Neil Mehltretter, Technical Director, Kaeser Compressors

Each year tens of thousands of compressed air assessments and audits are conducted, and each year significant savings are identified. Most of these assessments begin with a common goal or purpose, whether plant-centric or as a corporate edict and overwhelmingly tend to focus on energy savings. However, to only focus on energy savings omits many other opportunities within an assessment such as the two we’ll focus on in these case studies; leaks and moisture problems. For both case studies we’ll look at data from the existing system, the unique solutions that were discussed to solve each problem, as well as the overall factors that go into station design.

As Technical Director, Neil Mehltretter oversees Kaeser’s Technical Department with responsibilities including product management and system design. 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. He is the Chair of the Compressed Air & Gas Institute’s System Assessment Section. He has a bachelor’s degree in chemical engineering from The University of Florida and holds several industry certifications.

Speaker #2: Compressed Air System Optimization: Data-Driven Redesign for Reliability & Efficiency

Tony Taylor, Assessment Training & Process Manager, Ingersoll Rand

This presenter will review the analysis and corrective actions implemented for two industrial compressed air systems utilizing centrifugal and rotary screw compressors. The case studies explore failure points, inefficiencies and moisture issues in legacy systems. Each study details the original conditions, measurement methodology and post-analysis recommendations including compressor upgrades, cleanup equipment and energy-saving strategies. Attendees will gain insights on how to approach complex system redesign using empirical data, modeling and operational requirements. Quantified results and visual data will be presented.

Tony Taylor is the Assessment Training and Process Manager at Ingersoll Rand. He holds a Master of Science in Mechanical Engineering with a concentration in Thermal and Fluid sciences and a minor in Mathematics. With over a decade of experience in compressed air systems, Taylor started as an assessment engineer and quickly became known for developing practical, data-driven tools that enhance diagnostics, system evaluation and reporting.  His innovations – ranging from reliability scoring apps to performance analysis workbooks—are now widely used across Ingersoll Rand’s Assessment and Sales Teams. He has also led a cultural shift within the company, promoting open knowledge sharing, mentorship, and tool accessibility to strengthen the organization’s technical capabilities.

Speaker #3: Improving Resilience & Efficiency with Environmental Controls & Breakdown Prevention

Douglas Thieme, Western Regional Sustainability Consultant, Atlas Copco Compressors

This case study examines a critical failure in a large, compressed air system at a manufacturing facility that was using four 1,000HP centrifugal compressors for their low-pressure system, which supplied control air and baghouse systems. A malfunction in the baghouse filtration system led to dust accumulation, pressure drop and compromised suction pressure, which the plant mistakenly attributed to compressor or control issues. Despite early identification during an air audit, lack of corrective action caused the inlet header to implode, resulting in catastrophic system failure. The findings provide actionable insights for improving system resilience and preventing similar breakdowns in other industrial applications.

The next case study highlights operational challenges faced by a manufacturing facility running four double-acting reciprocating compressors totaling 2,000HP. Despite relocating equipment to a basement to avoid process dust, the system remained vulnerable to contamination and extreme heat, causing doors to pull open from room vacuum and temperatures exceeding 100°F. A proposed chimney stack ventilation system significantly mitigated these issues by sourcing cleaner air and automatically exhausting excess heat. The upgrade led to reduced compressor runtime, with two units inactive 90% of the time, and achieved full ROI in just two months.

As Western Regional Sustainability Consultant, Douglas Thieme oversees Atlas Copco’s Airscan Auditing Division for 13 states in the Western Region. He provides consultation, manages an auditing team and performs energy assessments and services to end users. Thieme has been performing energy assessments for over 25 years. He has consulted for a wide range of end users from food and beverage, bio-med, micro-semiconductors, steel and oil and gas companies. Over the years he has performed not only compressed air studies but assessments for a myriad of end use process equipment as well as support equipment such as cooling towers, chillers, refrigeration, vacuum, blowers and hydraulic systems.

Speaker #4: Strategic Compressed Air System Capacity Enhancement & Expansion

David Sleeman, Director of Aftermarket Sales, FS-Elliott

A leading car manufacturer needed to boost compressed air capacity without costly new equipment or downtime. By re-rating existing compressors with aerodynamic upgrades, they met growing production demands, saved energy, and avoided major capital expenses – proving that smart innovation can unlock powerful results from legacy systems. Next, we will examine how a molded plastics plant improved air system reliability and lifecycle costs after transitioning from positive displacement air compressors to oil-free centrifugal technology. Learn how these methods are optimizing compressed air systems in demanding manufacturing environments.

From the field to the boardroom, David Sleeman, Director of Aftermarket Sales with FS-Elliott, brings decades of hands-on compressor expertise, global aftermarket leadership and extensive technical training in oil-free compressed air systems, electrical diagnostics and industrial safety to share real-world strategies that drive growth and reliability in compressed air solutions.

OPENING SESSION

Tuesday, October 21, 2025, 10:15 – 12:00 PM. Join us in room 2103AB for The Opening Session.

Attendees will earn 2 PDH credits.

Wednesday, October 22, 08:00 – 10:00 AM

Session #2: Hidden Gold in Compressed Air & Cooling Systems

Chair: Andy Poplin, Senior Vice President Industrial Products Group

Speaker #1: The Hidden Gold in Waste Heat: Heat Recovery Systems for Industrial Applications

Andy Poplin, Senior Vice President Industrial Products Group, Atlas Machine & Supply

This presentation will share how you can improve energy efficiency and lower operating costs by capturing and reusing waste heat from industrial processes, HVAC systems or exhaust streams to reduce overall energy consumption. Explore how decreasing energy usage leads to lower greenhouse gas emissions and a reduced carbon footprint. Discover how heat recovery can be integrated into various systems like boilers, air compressors, ventilation units and chillers. Many heat recovery systems offer a strong return on investment, with payback periods often under two years depending on application and energy prices.

Andy Poplin, Senior Vice President Industrial Products Group, Atlas Machine and Supply, oversees strategic growth, customer engagement and operational performance across a range of industrial equipment and service solutions. A mechanical engineer by training and a leader by passion, Poplin earned his Bachelor of Science in Mechanical Engineering from the University of Kentucky. With more than 30 years in the compressed air industry, he has built and led teams that deliver real-world impact for manufacturers across the region. Poplin brings deep insight into industrial distribution, energy conservation and the evolving role of engineering in today’s business landscape.

Speaker #2: Plastics Industry: Chilled Water Energy & Water Conservation Projects

Roger Schmitt, Sales Engineer, Gem City Plastic

Learn about the various components used in the plastics industry that consume energy and water, and how to improve on saving utility usage. The presentation will touch on how savings of energy and water can be achieved through electrical and hydro modifications, discuss eliminating city water usage via process cooling, chilled water systems and explore new technologies in refrigeration components and their impact on energy savings.

Roger Schmitt has nearly 30 years’ experience in industrial sales and service, working for companies like Airtek, Parker Hannifin, Pfannenberg and Mokon. He has experience in application engineering for many process cooling projects involving a span of industries such as plastics, pharmaceuticals, food and beverage, solar energy, automotive, etc. Schmitt currently works for Gem City Plastic Machinery, a representative covering the state of New York and North Western Pennsylvania that concentrates largely in the plastics industry.

Speaker #3: Beyond the Usual Suspects: Finding Often Overlooked Value in Compressed Air Systems

Paul Edwards, Principal, Compressed Air Consultants

Compressed air is often treated as a technical utility – something to be optimized through leak surveys, control upgrades or capital projects. But meaningful, long-lasting improvement requires more than checking boxes. It demands a deeper understanding of how the system functions within the broader plant environment and how different parts of the organization define success.

This session explores how reframing compressed air as a business process can uncover value that’s routinely overlooked. Part of that is the who, understanding what different roles across the organization truly care about. Part of it is the what, recognizing the broader set of factors that elevate the outcome of a project. And the why is simple: when you approach things differently, the process becomes more meaningful, your skills evolve and your ability to make a lasting impact on your plant or your client’s plant grows with it.

After graduating from the University of Virginia with a BSME, Paul Edwards went to work for Ingersoll Rand in positions from the field to global and national responsibilities. He started Compressed Air Consultants in 2003 as an independent compressed air system consultant. The company performs audits, detailed design and projects.

Speaker #4: Manufacturing Heat Recovery Opportunities & Analysis Methods

Philip Johnston, Director, E4E Solutions

Most manufacturing facilities have an untapped resource that can be leveraged to conserve energy and improve the environmental impact of the operation – waste heat. This session will provide an overview of common opportunities with heat recovery in industrial manufacturing facilities as well as approaches to analysis of those opportunities. Important to understand concepts like pinch analysis, system design and identifying sources and sinks will be covered. The presentation will include some real-world examples of projects that use these concepts to deliver energy savings and carbon emissions reduction.

Philip Johnston, Director, E4E Solutions, is a licensed mechanical engineer with over a decade of experience in providing energy and decarbonization projects for industrial clients. Over the years, he has performed all aspects of an energy project including energy auditing, detailed engineering design and project implementation. He has a passion for meaningful engineering work that improves the environment and helps businesses at the same time.

PLENARY SESSION

Wednesday, October 22, 2025, 10:15 – 12:00 PM. Join us in room 2103AB for The Plenary Session.

Attendees will earn 2 PDH credits.

Thursday, October 23, 08:00 – 10:00 AM

Session #3: Fundamental System Design, Control and Component Selection

Chair: Clayton Penhallegon, Jr., Principal Engineer, Integrated Services Group

Speaker #1: Maximizing Chiller Efficiency: It’s Not Just About the Chiller!

Clayton Penhallegon, Jr., Principal Engineer, Integrated Services Group

This presentation will explore how true system performance depends not only on selecting an efficient chiller, but on optimizing the entire cooling system. It will review key chiller selection criteria and design efficiency capabilities, while also highlighting the critical role of supporting components – such as cooling towers and pumps. Designed for factory personnel, engineering firms and equipment sales engineers, this presentation offers practical insights to ensure chillers perform efficiently in the field.

Clayton Penhallegon, Jr. is the Managing Member of Integrated Services Group, which provides process cooling water system operational effectiveness, cost reduction consulting services and project implementation for manufacturing facilities. 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.

Speaker #2: Most Open Valve Control Drives Major Aeration Blower Efficiencies

Bob Kisler, Sales Manager, Hoffman & Lamson

In order to maintain an aerobic biological process, it’s necessary to maintain the appropriate dissolved oxygen (DO) concentration in the basin. Inadequate DO can result in poor treatment, but excess DO wastes energy without improving treatment. Control of the DO concentration is generally the most cost effective method of optimizing aeration energy. A properly operating DO and aeration control system can save 25-40% of the energy used by manually controlled systems.

Bob Kisler, Sales Manager, Hoffman & Lamson, has over 35 years in the compressed air industry, concentrating on improving procedures. His current responsibilities include developing and implementing new products for process improvement, consultation with a means of providing solutions, technical assistance on energy savings with centrifugal blower technologies and focus on the use of VFD and PLC controls to reach maximum energy savings for blower applications.

Speaker #3: Improving Energy Efficiency and Reliability through Pump System Optimization

Matthew Derner, Senior Manager, Education and Training, Hydraulic Institute

This presentation builds on fundamental principles to examine the economics of pumping systems and the strategies to assess and optimize these systems. It’ll cover a critical skill set that is required to analyze and optimizing pumping systems by reducing energy and maintenance costs. This presentation provides immersive coverage of pump system economics, optimization based on life cycle cost and standardized processes to assess and improve pumping systems.

Matthew Derner is the Senior Manager, Education and Training at the Hydraulic Institute. He holds a leading role in promoting pump system related programs that deliver energy efficiency in commercial and industrial settings. Additionally, he is responsible for managing Pump Systems Matter, HI’s training subsidiary, and for the overall promotion and growth of the organization’s portfolio of training and certification programs that focus on pump system optimization and efficiency. Derner has a strong background in global sales of pumps, drives and various rotating equipment in both the manufacturing and distribution segments, with an emphasis on energy efficiency and total cost of ownership.

Speaker #4: Motor & Drive Selection for Reliable Operation of Air Compressors

Luke Buschman, Business Development Manager, ABB

This presentation explores how the right motor and drive package provides reliable operation of compressors. Synchronous reluctances motors run with lower bearing and winding temperatures, which further increases reliability. Variable speed drives enable a more efficient operation, extension of the equipment lifetime and cost savings. Drives offer a broad communication compatibility with the automation networks and systems for plants. They also have integrated safety features around speed and torque that reduce the need for external safety components.

Luke Buschman, Business Development Manager – Drive Products, ABB, has nearly a decade of experience around automation sensors, process equipment, safety and variable speed drives.

Thursday, October 23, 10:15 AM – 12:15 PM

Session #4: Compressed Air Data, Measurement and AI

Chair: Mustafa Uslu, General Manager, Revindus

Speaker #1: Flow Measurement Techniques and the Air Compressor Performance Verification Program

Mustafa Uslu, General Manager, Revindus

Ensuring the performance of air compressors poses significant challenges but holds paramount importance within the industry. This presentation will analyze the various flow measurement techniques used for verifying compressor performance. It will also explore the rationale behind the selection of the “Sonic Nozzle” flow meter by the CAGI Intertek lab and the portable applications employed for on-site CAGI-Wise verification.

Mustafa Uslu, General Manager, Revindus, has over 15 years of experience in designing, developing and manufacturing high tech compressed air equipment and special refrigeration units. Uslu holds a master’s degree in Mechanical Engineering.

Speaker #2: Machine Learning-Based Virtual Sensors for Real‑Time Diagnostics of Compressed Air Systems

Miha Lazar, Data Scientist, CALMS Air

A virtual sensor is a software‑derived measurement that estimates a physical parameter – such as flow, power consumption or specific energy – using machine‑learning models trained on existing plant data sets (typically 10-100 sensor channels).

This presentation outlines a systematic workflow for developing, validating and deploying virtual sensors in compressed‑air installations. Key topics include data‑quality requirements, feature engineering, model‑selection criteria and integration with supervisory control systems. Several industrial case studies will be shared, including a centrifugal compressor flow application where a virtual sensor identified a 12% performance deviation masked by a faulty dew‑point transmitter. The results demonstrate that properly designed virtual sensors can operate alongside hardware instrumentation to improve diagnostic coverage, reduce maintenance costs and support continuous energy‑efficiency improvement.

Miha Lazar earned a master’s degree in Electrical Engineering from the University of Ljubljana’s Faculty of Electrical Engineering. His early research at CALMS focused on quantifying compressed air leaks and calibrating ultrasonic leak detectors. He has also held roles in production planning and quality control. Lazar currently serves as Lead Project and Data Scientist at CALMS, where he analyzes compressed air systems and develops data‑driven diagnostic solutions.

Speaker #3: The Physics Behind Compressed Air: Key Equations for Efficiency

Andrew Smith-Carrier, Founder, SMARTCAir

Understanding compressed air systems starts with the fundamental equations governing air compression and flow. This presentation will break down the key first-principles equations – such as those defining power, pressure and mass flow – and explain their direct connection to rotary screw air compressor performance and overall system efficiency.

It’ll explore how factors like system volume, duty cycle and air properties influence energy consumption, and why common “rule of thumb” approaches often miss critical efficiency gains. Real-world case studies will illustrate how applying these principles can significantly reduce costs, improve reliability and optimize system operation. Attendees will leave with a clearer grasp of how to apply physics-based insights to improve compressed air efficiency in their facilities.

Andrew Smith-Carrier, P.Eng., M.A.Sc., is a mechanical engineer with over 15 years of experience in compressed air auditing, modeling and system optimization. With a strong foundation in first-principles engineering, he has worked extensively on improving the efficiency and performance of industrial compressed air systems. Smith-Carrier co-founded a startup focused on cloud-based compressed air monitoring and control, integrating real-time data with advanced analytics and has also led the development of an innovative online modelling tool that applies first-principles physics to compressed air simulation, system analysis and reporting.

Speaker #4: Powering Plant Efficiency: DOE’s Free MEASUR Software and Better Plants Program

Alex Botts, R&D Associate, Oak Ridge National Lab

Learn how MEASUR’s tools support system assessments and performance optimization, making it easier to justify and prioritize improvements. Hear how the Better Plants Program offers resources, workforce development opportunities and technical assistance to help companies set and meet energy reduction goals. Whether you’re conducting audits, making efficiency recommendations or managing plant operations, you’ll leave with actionable strategies and tools to drive real results.

Alex Botts, CEM, is a Technical Account Manager at Oak Ridge National Laboratory supporting the U.S. Department of Energy’s Better Plants and Better Climate Challenge Programs. She provides technical assistance and strategic guidance to industrial partners, specializing in compressed air systems, DOE’s MEASUR software and utility analysis using the VERIFI platform. Botts led the redevelopment of the legacy AirMaster+ tool, co-leads ORNL’s role in the ITAC Implementation Grant program, and serves as Vice President of the East Tennessee AEE chapter. She is also a regular columnist for Compressed Air Best Practices Magazine and an active leader in energy assessments and workforce training initiatives.