Case Study

Powering an Expansion: Flying Spares

A new compressed air system designed, installed, and commissioned for Flying Spares' expanded facility. Variable speed technology cut energy consumption and delivered measurable savings from day one.

4,322 kWh saved per year
£1,729 Annual cost saving
18.5kW VSD compressor installed
5yr Service plan included
The Goal

A Bigger Facility Needed a Better System

Flying Spares is a specialist provider of parts for luxury and classic cars. Growing demand meant a move to a larger facility with a more extensive workshop area. The existing 11kW fixed-speed compressor was no longer adequate for the expanded operation.

As a long-standing Airmech customer, Flying Spares needed a compressed air system that could support the larger site while keeping energy costs under control. The new facility required clean, dry air delivered reliably across the full workshop floor.

The brief: design and install a complete system from scratch. Compressor, dryer, filtration, pipework, and hose reels, all commissioned and ready for the day the new site opened.

“The expertise and tailored solutions from Airmech were crucial during our site expansion. Their advanced compressed air system not only enhances our operational efficiency but also offers significant energy savings.”

Andy Thwaites, TSD Manager, Flying Spares
The Solution

A Complete System Designed for Efficiency

Airmech designed and installed a complete compressed air system tailored to Flying Spares' specific requirements. The centrepiece: an 18.5kW variable speed screw compressor with an integrated dryer.

What was installed

  • 18.5kW variable speed screw air compressor with integrated dryer
  • Two inline filters to maintain air purity for high-quality automotive work
  • Oil water separator for environmental compliance
  • Compressed air aluminium ring main with quick release fittings
  • Multiple hose reels positioned across the garage workshop

The variable speed drive adjusts motor speed to match actual air demand in real time. Unlike a fixed-speed machine that runs at full power regardless of load, the VSD compressor scales up and down throughout the day, eliminating wasted energy during low-demand periods.

The Impact

More Capacity, Less Energy, Lower Costs

Despite moving from an 11kW fixed-speed compressor to an 18.5kW variable speed model (nearly double the capacity), Flying Spares saw a significant reduction in energy consumption. The variable speed technology more than offset the larger motor size.

4,322 kWh annual energy savings. Variable speed drive reduced consumption despite the larger compressor capacity.
£1,729 annual cost saving on energy bills. Payback from the VSD technology starts immediately.
22,847 kWh new annual consumption. A bigger system running more efficiently than the smaller one it replaced.
14% maintenance cost saving over five years through Airmech's proactive service plan with fixed pricing.

Flying Spares also benefits from a five-year service plan with maintenance intervals based on actual run hours rather than a fixed calendar. Digital records, scheduled reminders, and a single point of contact for everything from routine servicing to emergency support.

Services Deployed

Installation and Commissioning

Complete system design, installation, and commissioning. Compressor, dryer, filtration, pipework, and hose reels delivered ready for day one.

Compressor Servicing

Five-year proactive service plan with maintenance tailored to actual run hours. Fixed pricing with 14% saving over the contract term.

Air Treatment

Integrated dryer, inline filtration, and oil water separation ensuring clean, dry air for precision automotive work.

Planning a New Installation or Site Move?

We design, install, and maintain your compressed air system as one package. One partner from day one.

Talk to a Compressed Air Specialist Call 02476 345 658