Turbo Blowers: Energy-Saving Blower Technology

The industrial world is changing. Where previously the focus was on reliability and acquisition costs, today it increasingly revolves around efficiency, energy savings and sustainability. Companies are constantly looking for ways to optimize their processes without compromising on performance. That's precisely why blower technology is increasingly in the spotlight.

Whether it's drying packaging, aerating water basins, cooling products or generating process air, many industrial processes are powered by blower installations. And although these installations often function flawlessly for years, closer examination frequently reveals that there is much to gain in terms of energy consumption.

In recent years, we at DOVAC have seen a clear shift in the market. More and more companies are switching from traditional blower technology to modern turbo blowers. Not because existing technologies no longer function, but because turbo blowers can be considerably more efficient in many situations.

As the exclusive distributor of both Master Blower and Galex Air for the Benelux, we see daily how this technology helps companies reduce energy costs, improve processes and make installations future-proof.

In this blog we dive deep into the world of turbo blowers. We explain what a turbo blower is, how this technology works, what the differences are with roots blowers and side channel ventilators and why turbo blowers are increasingly being applied in air knives, water treatment, aeration and industrial process air.

What is a turbo blower?

A turbo blower is an advanced blower that moves air using a high-speed impeller. This impeller rotates at very high speeds and accelerates the air extremely efficiently before it is directed to the process.

Unlike many traditional blower technologies, air is not mechanically displaced, but aerodynamically accelerated. This creates a more efficient process where less energy is wasted. This may sound like a technical detail, but in practice it makes an enormous difference.

Due to their high speeds, turbo blowers can deliver large air volumes from a relatively compact machine. Additionally, modern turbo blowers often feature frequency regulators that allow capacity to be continuously adjusted to actual air demand. This creates an installation that doesn't produce more air than is actually needed. And that's exactly where the biggest savings lie.

Why energy consumption has become more important than purchase price

When a company invests in a new blower installation, the purchase price is often the first thing looked at. That makes sense. But with blower installations, the purchase price often represents only a small part of the total cost over its lifetime.

The real costs are usually in energy consumption. A blower running eight hours a day easily produces more than 2,000 operating hours per year. Within many production facilities, water treatment plants and process installations, a blower runs 24 hours a day. As a result, relatively small differences in power can make thousands of euros difference on an annual basis.

A blower that consumes only a few kilowatts more than necessary can cause many times its purchase price in additional energy costs over its lifetime. That's why more and more companies are looking at energy-efficient alternatives. Turbo blowers play an important role here. Not because they are necessarily cheaper to purchase, but because they often consume significantly less energy over their lifetime.

Turbo blower versus roots blower

Roots blowers have been used in industry for decades. They are robust, reliable and suitable for a wide range of applications. Many companies have been working flawlessly with roots blowers for years. Yet every technology has its limitations.

A roots blower works with two rotating lobes that mechanically displace air. This system works excellently, but also brings internal losses with it. In addition, roots blowers produce relatively high heat and noise.

A turbo blower works fundamentally differently. By aerodynamically accelerating the air, a more efficient process is created. Moreover, modern turbo blowers can continuously adjust their capacity to actual air demand. This means no longer having to continuously operate at maximum capacity. Especially with installations running day and night, this can make a huge difference.

It is important to emphasize that roots blowers are absolutely not outdated. For certain applications they remain an excellent choice. But increasingly we see situations where a turbo blower proves to be more efficient.

Turbo blower versus side channel ventilator

Side channel ventilators also play an important role in industrial air technology. DOVAC has been supplying side channel ventilators for many years for applications such as vacuum lifting, aeration, air transport, drying and process air.

They are reliable machines that function excellently in many situations. Yet an interesting playing field also emerges here. When an application requires relatively high pressures or vacuum levels, a side channel ventilator often remains the most logical choice.

However, when very large air volumes are required, a turbo blower can offer advantages. That's why at DOVAC we always look at the complete application. Not technology is central, but the process. The question is not which blower is best. The question is which blower best suits the application.

Compressed air: the most expensive form of process air

Many companies have an extensive compressed air network. This often creates a tendency to use compressed air for all kinds of applications. From cleaning to drying. From product cleaning to cooling. Yet it is often underestimated how much energy is needed to produce compressed air. Compressors must compress air to high pressures. This process requires a lot of energy. When this expensive compressed air is subsequently used for applications that mainly need air volume, a relatively inefficient situation arises.

That's why turbo blowers are increasingly being deployed as an alternative. Especially with air knives, we regularly see that a turbo blower can deliver the same or even better performance at significantly lower energy costs.

Turbo blowers and air knives: a perfect combination

If there is one area of application where turbo blowers have gained significant ground in recent years, it is air knives. Air knives are used for drying, cleaning and cooling products.

Think for example of:

• bottles
• jars
• packaging
• vegetables
• fruit
• plastic parts
• metal components

An air knife creates a powerful and uniform air film over a product. This allows water droplets, dust particles and other contaminants to be efficiently removed.

What's special is that an air knife mainly needs large air volumes.

And that's exactly where a turbo blower excels.

Master Blower: developed for maximum efficiency

Within DOVAC's range, Master Blower occupies a special position. Not only because DOVAC is the exclusive distributor for the Benelux, but especially because this technology perfectly addresses the challenges many production companies face today.

Master Blower was developed with one clear objective: to move large quantities of air with the lowest possible energy consumption.

That sounds simple, but in practice it's a huge challenge. As air volumes increase, energy consumption with many traditional blower technologies also rises significantly. Especially with installations running many hours a day, this becomes directly visible on the energy bill.

The turbo blowers from Master Blower are specifically developed to address this problem. By using modern high-speed technology, high efficiency can be achieved, even when large air volumes are required.

This creates an interesting solution for companies that not only need more capacity, but also want to reduce their operational costs.

Why air knives are increasingly combined with Master Blower

At DOVAC we have been supplying air knives for various applications for many years. This is why we see daily what challenges companies face.

• A product needs to dry faster.
• A conveyor belt becomes wider.
• A production line runs at higher speed.
• Or a company wants to get rid of the high energy consumption of compressed air.

In all these situations, the air supply plays a crucial role.

Many people look first at the air knife itself, while the blower behind the system is often at least as important. An air knife functions optimally when it has a large amount of air that is evenly distributed across the full length of the profile. That's exactly where Master Blower's strength comes through.

By efficiently delivering large air volumes, a powerful air film is created with which products can be dried, cleaned or cooled quickly and effectively.

Especially within the food industry, packaging industry and plastics processing industry, we increasingly see combinations of air knives and turbo blowers.

Practical example: drying packaging

A common application is drying packaging after a rinsing or cleaning process.

Packaging that is wet when entering a labeling machine can cause problems. Labels adhere less well, markings become less readable and packaging processes can be disrupted.

Traditionally, this was often solved with compressed air. That worked fine. But the energy costs were high.

By switching to a combination of air knives and an energy-efficient turbo blower, the same or even better drying result can often be achieved at considerably lower operating costs.

The nice thing about this is that the savings return every day. Not just once at purchase, but throughout the entire life of the installation.

Energy savings in practice

One of the first questions we receive when a company shows interest in turbo blower technology is:

"How much can we save?"

This varies of course depending on the application. Yet we regularly see impressive results.

Suppose an existing installation operates with a 13 kW blower.

When the same application can be performed with a 5.5 kW turbo blower, a saving of 7.5 kW per operating hour is achieved.

At an electricity price of € 0.50 per kWh, this means:

• € 3.75 per hour
• € 30 per day
• € 600 per month
• approximately € 7,200 per year

For companies with multiple installations or 24-hour production, these amounts can be considerably higher.

And we've only looked at energy consumption.

Benefits such as less heat generation, lower maintenance costs and a more stable process haven't even been taken into account.

Galex Air: intelligent turbo blower technology

In addition to Master Blower, DOVAC also represents Galex Air in the Benelux. Where Master Blower strongly focuses on efficiently generating large air volumes, Galex Air emphasizes intelligent control and process optimization.

The Axion One series was developed for companies that want to maintain maximum control over their process. Increasingly, installations are controlled based on data. Sensors measure oxygen values. PLC systems monitor processes. Energy management systems record consumption.

Within this environment, there is a need for blower technology that can flexibly respond to changing circumstances. And that's exactly where Galex Air excels.

Why frequency control is becoming increasingly important

Many traditional blower installations operate at a fixed capacity. Whether lots or little air is needed, the blower continues to deliver the same power. That's simple, but not always efficient.

A modern turbo blower works differently. When air demand decreases, the blower automatically lowers its speed. When more capacity is needed, the blower increases its performance.

This means energy is used only when actually needed. Especially with installations with variable loads, this can make a big difference. Not only in terms of energy consumption, but also for process stability.

Turbo blowers for water treatment

One of the most important areas of application for Galex Air is water treatment. Within biological water treatment, oxygen plays a crucial role.

Bacteria use oxygen to break down pollutants. Without sufficient oxygen, the efficiency of the treatment process declines. That's why large quantities of air are introduced into the water.

The problem is that aeration is often one of the largest energy consumers of the entire installation. In some cases, more than half of the total energy consumption is directly linked to the aeration process. That's why interest in turbo blowers is growing.

By producing air more efficiently and controlling it more intelligently, energy consumption can be significantly reduced without compromising on performance.

More oxygen with less energy

The ultimate goal of aeration is not to produce as much air as possible. The goal is to get enough oxygen into the water. This may seem like a small difference, but it's essential.

An efficient turbo blower ensures that exactly the right amount of air is delivered at the right time. This creates a stable oxygen level while preventing unnecessary energy consumption.

For water treatment plants, process installations and industrial aeration systems, this can be an important step towards lower operating costs.

Turbo blowers in horticulture

Interest in turbo blowers is also growing rapidly within horticulture. That's not surprising. Modern horticultural companies continuously invest in more efficient processes, lower energy costs and better water quality. Water plays a crucial role in virtually every crop.

Many companies use water basins, silos and recirculation systems in which water is stored and reused. To maintain the quality of this water, sufficient oxygen is essential. When oxygen levels drop, this can have negative consequences for water quality and ultimately for the crop. That's why aeration systems are increasingly being applied.

Traditionally, this was often done with roots blowers or other conventional blower technologies. Although these systems still function, we see that more and more companies are switching to modern turbo blowers. Not only because of energy savings, but also because of better controllability and higher efficiency.

Especially within larger horticultural companies where installations run day and night, this can lead to significant cost savings.

Aeration of water basins

Aeration may seem simple at first glance. Air is introduced into the water and the job is done. In reality, much more is involved.

The amount of oxygen that actually reaches the water is influenced by various factors such as:

• air capacity;
• pressure;
• basin depth;
• diffusers used;
• air distribution;
• operating conditions.

A well-designed aeration system therefore doesn't revolve around producing as much air as possible. It's about efficiently transferring oxygen to the water. Modern turbo blowers are specifically developed with this goal in mind. Due to their high efficiency, they can deliver large quantities of air without requiring excessive energy. This creates a more stable process and a lower energy bill.

Practical case study: more oxygen and lower energy consumption

We saw a good example of this at a company active in industrial water treatment. The existing blower installation was still functioning, but the results were not optimal. The oxygen level was lagging and at the same time energy consumption continued to rise.

The first thought was to overhaul the existing blower. However, analysis showed that the technology itself had become the limiting factor. Together with the customer, we looked at a modern alternative.

After switching to a turbo blower, several benefits emerged immediately. The oxygen level in the water improved significantly. The process became more stable. And energy consumption dropped sharply.

What this situation particularly shows is that the biggest gains are often not achieved by simply replacing an existing installation with the same type of machine.

The real gain emerges when the complete application is considered.

That's exactly where the power of modern turbo blower technology lies.

Less noise, fewer vibrations and less maintenance

When companies think about a new blower installation, the focus is often on capacity and energy consumption. That makes sense. Yet other benefits are regularly underestimated.

Many traditional blower installations produce relatively high noise levels. Especially older roots blowers are known for their characteristic noise and vibrations. Within production environments, this can lead to a less pleasant work environment.

Turbo blowers often have a much quieter character. Their modern design results in fewer vibrations and lower noise levels. This not only provides greater comfort, but can also contribute to a longer life of the installation.

Furthermore, modern turbo blowers are designed with reliability as a starting point. Less mechanical stress often means less wear. For companies where downtime costs money directly, that's an important advantage.

Why DOVAC looks beyond just the blower

At DOVAC, we don't believe in simply supplying a machine. After all, a blower is only one part of a complete installation. Ultimate performance is influenced by many more factors.

Think for example of:

• pipe diameters;
• filters;
• silencers;
• air knives;
• control systems;
• operating hours;
• process conditions.

That's why good advice always starts with understanding the application.

• What needs to happen?
• How much air is really needed?
• What technology is currently being used?
• How much energy is being consumed?
• What improvements are being sought?

Only when these questions are answered does a complete picture of possibilities emerge.

Sometimes a Master Blower turns out to be the ideal choice. Sometimes Galex Air fits better. And in other situations, a side channel ventilator or other blower technology remains the most logical solution.

The goal is not to sell a blower. The goal is to improve a process.

Why turbo blowers will play an important role in tomorrow's industry

Industry faces major challenges. Energy costs continue to rise. Sustainability becomes increasingly important. Companies must remain competitive in a market where efficiency is central.

This grows the need for technologies that not only function well today, but are also ready for the future. Turbo blowers fit perfectly with this development.

Through their combination of:

• high efficiency;
• low energy costs;
• intelligent control;
• high reliability;
• low maintenance requirements;

they represent a logical step towards modern industrial processes.

Whether it's air knives, process air, water treatment, aeration or other industrial applications, turbo blowers will play an increasingly larger role in the coming years.

Conclusion

Turbo blowers are much more than an alternative to traditional blower technology. They form a modern solution for companies that want to reduce energy consumption, optimize their processes and be prepared for the future.

Master Blower stands out for powerful air displacement and maximum efficiency in applications with large air volumes, such as air knives, drying processes and process air.

Galex Air adds intelligent control and advanced process control, making this technology particularly interesting for water treatment, aeration and other dynamic processes.

Which solution fits best depends entirely on the application.

That's why DOVAC looks beyond just the blower. By analyzing the complete process, we can advise which technology delivers the highest efficiency, greatest energy savings and best performance.

Want to know more about Master Blower or Galex Air?

Are you curious how much energy you can save with a turbo blower?

Or would you like to know if a Master Blower or Galex Air is suitable for your application?

DOVAC will be happy to advise you on:

• turbo blowers;
• air knives;
• process air;
• water treatment;
• aeration;
• energy savings;
• industrial blower installations.

Feel free to contact us for technical advice or an analysis of your current installation.

Together we'll see how your process can become more efficient, more sustainable and more energy-efficient.