Project to fulfil increased compressed air demand for automotive customer of over 20 years

Dennis Eagle are manufacturers of refuse collection vehicles and are world leaders in the design and production of these vehicles. The company are consistently known for achieving the highest performance, cost, and delivery expectations within the quality products that they supply.

Dennis Eagle use compressed air for applications across the shop floor, including paint booths, paint sprayers, air filtration vent masks and air tools. However, the biggest compressors support their shotblast areas.


The Brief

John Johnson, Dennis Eagle’s Production Manager, helped identify the requirements of the shotblast plant project. The customer needed greater capacity within their compressed air system due to an increase in production, on top of a general upgrade of the equipment to refresh their system and consequently save energy.


Our Solution

Direct Air worked hard to find the best solution for the customer of over 20 years, providing a selection of potential options available to fit their requirements. Allan Dolby, Managing Director at Direct Air, recommended a CompAir L110RS Variable Speed Compressor and new CompAir L80 Fixed Speed Compressor, alongside 2 large receivers and the required downstream equipment.

These machines were installed alongside the customers’ existing CompAir L90, increasing the compressed air systems maximum capacity from 1,297 cfm to 1,817 cfm. This provided the required capacity for the shotblasting compressed air increased demand of 1,536 cfm.

To accompany the new machines, a pipework system was implemented involving valves to produce multiple outputs. Pipework was also sent off ahead of the installation to be manufactured into the unique structure, utilising the help of our bespoke in-house CAD CAM capabilities.

The new equipment meant that the customers initial £16,000 per annum of wasted energy was reduced. Therefore, saving the customer money whilst improving the compressed air systems efficiency and productivity.


Dennis Eagle’s Production Manager, John Johnson commented:

“Dennis Eagle have been using Direct Air for many years so when a big project came up it was a no brainer to call the team. A service provider who are reliable, knowledgeable, and only interested in the best possible solution. After many meetings on the shotblast project, we come up with a plan and we’ve never looked back – reduced the takt time and increased the output. Allan, John and the team completed a 10/10 job!”

Allan Dolby, Managing Director at Direct Air commented:

“The relationship with the customer is very good, with the response whenever visiting their site always being positive. Throughout the entire project, everyone worked efficiently together, which has maintained the strong working relationship. Having a helpful customer to cooperate with us along the way made all the difference!”