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About the Control Gear Group Control Gear employs over 100 staff and has an annual turnover approaching £16M.

The Control Gear Group of companies offers a unique service to industries in South Wales and the West Country. Since the formation of Control Gear Limited in 1973 – as a supplier of pneumatic control equipment and special purpose machines – the company has expanded continuously to serve other industrial areas.

Today, the Control Gear Group portfolio of quality products and service capabilities are completely unrivalled in the market place. They include the supply and service of the equipment in the field of:

SMARTPARTNERS

Control Gear has been associated with Atlas Copco for over 25 years and both companies enjoy a strong working relationship, with an emphasis on being a solutions provider of reliable, cost effective, energy efficient products.

Control Gear’s commitment to Quality, Health and Safety and the Environment has been endorsed by winning a Welsh Quality Award in the SME category and the company is accredited with ISO 9002, 14001 & 45001. All engineers are FGAS certified & Passport to Safety trained.

Investing in Quality PAGE

Control Gear 2 Our Product Ranges 3

Looking After Your Investment For Life Flexible Service Packages & Parts 4Guardian: 7 or 9 Years Warranty 5

Total Compressed Air ManagementFrom Generation to Point of Use 6Energy Recovery 7AirNet 8

Investing in Quality

Each distributor in Atlas Copco Compressors’ national network of Authorised Distributors has been specially selected as the best local air professional and has been factory-trained to the highest standards. Atlas Copco’s selection criteria is rigorous, and not everyone passes the grade, so whichever one you visit, you are guaranteed the full support and expertise you would expect from a world leader.

As an Authorised Distributor, we are fully backed by Atlas Copco, so you can be sure you’ll only be getting genuine Atlas Copco products and parts to keep your compressors running and your air system at its most energy efficient.

The legwork has been done for you, so when you’re looking for a highly trained and knowledgeable compressor expert, you just need to choose the Atlas Copco Compressors Authorised Distributor nearest to you.

SMARTPARTNERS The Advantages of Dealing With an Authorised Atlas Copco Distributor are Many

Oil Free Air Nitrogen Generation Quality Air Products Compressors Pneumatics

Industrial Power Tools Hydraulics Fluid Handling Finishing Equipment Industrial Filtration

Industrial Hose Pipeline Products Vacuum Pumps System Integration Remote Monitoring Solutions

Our Product Ranges

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PISTON COMPRESSORSAtlas Copco piston compressors are a simple, robust design and advanced in features and capability. This established compression technology allows Atlas Copco to focus on efficiency and versatility, creating compressors suitable for most industrial environments. Atlas Copco’s oil-lubricated LE & LT range can deliver compressed air up to 30 bar, whilst the LF, LFx & LZ range are quiet, compact and deliver 100% oil-free air.

NITROGEN GENERATIONAtlas Copco Nitrogen Generation systems with either Membrane or Pressure Swing Adsorption (PSA) technology allow you to produce your own nitrogen on site by using compressed air. Our NG products provide nitrogen to meet a wide range of flow, purity and pressure requirements, from 1 to 5000 Nm3/h and 95 to 99.999% purity. Onsite nitrogen generation eliminates the need for storing, reordering or changing bottles as nitrogen is available on tap 24/7. All in one, plug and play skid packages offer a solution for high pressure nitrogen requirements, with 40 Bar and 300 Bar variants. Our PSA units are the lowest energy consumption, lowest air factor in the industry and represent the lowest cost and energy supply method for nitrogen, compared to other generators, liquid and bottles.

QUALITY AIR PRODUCTSAir treatment products to remove moisture, oil aerosols, vapour and dust particles and ensure clean, dry air to expand the life of your equipment and ensure the quality of your end product. The wide range includes oil-water separators, filters, aftercoolers and air receivers, as well as refrigerant, heatless and heat regenerated desiccant adsorption air dryers, membrane and heatless and heat reactivated adsorption air dryers.

SCROLL COMPRESSORSThe SF and SF+ range of scroll air compressors are reliable, energy efficient and guarantee the delivery of 100% oil-free compressed air, certified to ISO 8573-1 Class 0 standard. Super quiet from 52 dB(A), and compact, they can be installed within any working environment and are ideal for dental and research laboratories. SF+ units incorporate the Elektronikon controller which provides enhanced monitoring features and easy control of multiple compressor installations.

SMALL ROTARY SCREW COMPRESSORSGX and G compressors bring the power and reliability of an industrial screw compressor to small and medium sized industry. Quiet operation and reliability make them suitable for continuous duty on a work site. These receiver- or floor-mounted machines are ideal for anything from automotive workshops to light manufacturing.

INDUSTRIAL ROTARY SCREW COMPRESSORS: FIXED SPEED, VSD & VSD+Premium GA & GA+ rotary screw compressors from 5-500kW to keep your production running smoothly. From tank-mounted workshop solutions with easy plug and play concept, through to workplace compressors with integrated air treatment equipment and Elektronikon Touch controller for easy monitoring and maintenance. Most models are also available with Variable Speed Drive technology which saves up to 35% on energy consumption.In addition, the innovative GA VSD+ variable speed drive compressors embody smart revolutionary design in a space saving vertical or compact horizontal configuration. VSD+ compressors reduce energy consumption by up to 50% thanks to an oil cooled, direct drive, interior permanent magnet motor that exceeds IE4 efficiency levels driven by a fully integrated variable speed drive. Available from 15 to 160 kW.

Investing in Quality

VACUUM PUMPS AND CENTRAL VACUUM SYSTEMSGHS VSD+ oil-sealed rotary screw vacuum pumps with VSD technology: a compact, complete and highly energy efficient central vacuum solution. Our wide range of vacuum pumps also includes rotary vane, dry screw, dry claw and liquid ring pumps, including the best in class liquid ring VSD+ range.

SERVICE PLANS

With a service plan, maintenance becomes a fixed operational cost with no surprises. Reliability is maintained by highly skilled service technicians who perform all needed interventions, using Genuine Parts at all times. Maintenance is done professionally, on time and quickly, resulting in the lowest cost of ownership for you. Our service plan portfolio responds to every customer need.

PREVENTIVE MAINTENANCE SERVICE PLAN

Preventive maintenance service plan offers on time servicing for your equipment. Tailored to your installation and site circumstances, the maintenance schedule always fits your needs, and gives you more uptime, better energy efficiency and increased reliability for a fixed fee and time. It lowers the risk of unexpected problems and alerts of possible issues so they can be solved and prevent breakdowns.

FIXED PRICE SERVICE

Fixed Price Services have a clear cost for each maintenance intervention, the scope of which is designed for your specific production needs. To limit your production downtime and allow you to allocate resources effectively, maintenance is scheduled ahead of time. Fixed cost includes all travel, material and labour. After each visit, your machine is left in the best working condition and with a comprehensive report of all actions completed.

OVERHAUL SERVICE

At the heart of every compressor, the elements (air ends) are vital to its performance. An Overhaul Service brings new life to your equipment, allowing you to enjoy another full cycle of risk-free operation. Air quality, reliability and performance are restored to the highest levels for many years to come.

An overhaul can be a considerable investment and Overhaul Service is a flexible solution that allows you to better control your operational budget. Scheduling the overhaul in advance gives you plenty of time to adapt your financial planning and ensures all resources and components will be available at the right time, for instance during a scheduled factory shutdown. Thanks to the expertise of our service engineers, the overhaul will be performed efficiently and swiftly, minimising downtime.

Our offer includes both new and refurbished elements which can be exchanged (conditions apply). The refurbished element (XChange Element) has a lower cost compared to a new one but still provides the same service length.

SERVICE AND SPARE PARTS

Requirements for service and maintenance are just as varied as the ranges of compressed air systems available. We offer flexible service tailored solutions to match your needs.

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Looking After Your Investment For Life

Flexible Service Packages & PartsThe best way to protect your investment is by looking after your equipment. Production performance is directly affected by the maintenance of compressed air equipment; it needs to be kept in optimal operating condition in all environments.

Our company and our people are committed to maximising the efficiency and reliability of your compressed air system. Our fully trained and accredited engineers and office support team are your SMART partners, close to you and close to your needs.

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Guardian is a 7 year service plan for the maintenance of your new compressed air installation from Atlas Copco UK, which validates your compressor’s 7 year FREE warranty. There is no catch – no hidden costs, no excess charges and no claim penalties.

The Guardian plan can be extended to 9 years and covers the entirety of your compressor room, not just the air compressor, ensuring your production has maximum uptime at the lowest possible operating cost.

Guardian comes in two options depending on your needs. It includes all regular preventive maintenance over 7 up to 9 years with genuine spare parts, oil, all labour and travel, breakdowns and overhauls, depending on the service plan option chosen.

By relying on scheduled service visits, spare parts availability and maintenance, in accordance with the manufacturer’s recommendations, your risk of production disruptions and unforeseen expenses is minimised. Guardian keeps your compressed air system running at optimum performance and in the most efficient way.

Looking After Your Investment For Life

Guardian Plus Guardian

7 or 9 year service plan

All parts and lubricants included for planned service

All labour included for planned service

Smartlink - if applicable

Upgrade available to Smartlink Uptime/Energy

All Breakdown spare parts covered Limited on drive train

All Breakdown labour covered Limited on drive train

Overhaul(s) included if applicable -

Choose the right level of Guardian Service Plan for your compressor room

Guardian: Choose 7 or 9 Years of Worry-Free Production

1. ANALYSE YOUR COMPRESSED AIR SYSTEM WITH AN AIRSCAN

With a service plan, maintenance becomes a fixed operational cost with no surprises. Reliability is maintained by highly skilled service technicians who perform all needed interventions, using Genuine Parts at all times. Maintenance is done professionally, on time and quickly, resulting in the lowest cost of ownership for you. Our service plan portfolio responds to every customer need.

A clear understanding of your compressed air system’s changing demands over time is the cornerstone in defining energy savings and improving energy efficiency. A complete AIRScan audit includes a full survey of all important compressed air installation parameters. Using the logged information, our compressed air experts will issue and deliver a comprehensive report, including cost analysis, graphs and the starting points towards improving your compressed air system. Through measurement and simulations an AIRScan identifies your savings potential.

AIRscan consists of:

Flow check – measure of flow on existing points or it can be “hot tapped” without system interruption.

Energy consumption audit iiTRAKs – measure and log current usage every second for a pre-determined period, usually 7 days for any type of compressors.

Leak check - between 10-25% of air consumption is down to leakage in most systems. Our audit identifies and quantifies these leaks, plus repairs can be done during the audit.

Air Quality check – measuring the compressed air quality and comparing it to your specific needs.

Maintenance review – assessing the effectiveness of your service programme for the whole compressor room.

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ENERGY SAVINGS Useful facts and figures about compressed air:

70% of the total cost of running a compressed air system is its energy consumption

1 kW of compressed air = 8 kW of electricity

Running a compressor at 1 bar lower in pressure reduces energy consumption by 7%

Typically, after 5 years, leakages account for 20% of the total air consumption. Most systems are not routinely shut down during non-production hours to maintain leaks

Improved compressor selections, based on your specific usage pattern, will provide further savings

Total Compressed Air Management

From Generation to Point of Use

Compressed air is one of the most important utilities for industry. But did you know that it is also one of the largest consumers of energy? Up to 70% of the life cycle costs of a typical fixed speed compressor is down to energy consumption. Therefore, any savings made in compressed air generation have a significant impact both on costs and on the environment.

Our approach focuses on reducing the overall energy bill, which means that we look through your compressed air installation, from compressed air generation to the distribution network and demand. This can be done in 3 steps. In Analysing, Optimising and Monitoring your compressed air installation, you will be able to minimise your cost and maximise your efficiency.

2. OPTIMISE YOUR ENERGY CONSUMPTION WITH CENTRAL CONTROLLERS

Atlas Copco central controllers link all compressors and dryers, lower your overall pressure band, eliminate the need for higher working pressure and optimise the compressor mix at all times.

The new generation OPTIMIZER 4.0 with a defined set-point can automatically operate the air compressors connected at lower pressure, thus reducing power consumption. Optimizer 4.0 is a flexible machine sequence controller selecting the most efficient combination at a defined working pressure, while balancing your units’ running hours.

Adapting to Industry 4.0, which pertains to the Internet of Things (IoT), OPTIMIZER 4.0 can gather data, store and analyse information that can be available in the cloud to be used to further improve an existing process or system. A perfect fit for Smart Factories.

3. MONITOR YOUR INSTALLATION WITH SMARTLINK

SMARTLINK is Atlas Copco’s user-friendly data monitoring

system. It gives you remote insight into your compressed air installation, helping to spot developing problems and even showing you the potential for optimisation and energy savings.

Choose from 3 levels of SMARTLINK to determine the amount of information you receive.

With SMARTLINK Service, a mouse click reveals the online service log. Get quotes for parts and additional service quickly and easily.

SMARTLINK Uptime additionally sends you an e-mail or text message whenever a warning requires your attention.

SMARTLINK Energy gives you customised reports on the energy efficiency of your compressor room, in compliance with ISO 5000.

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Total Compressed Air Management

Energy Recovery94% of the energy consumed by an air compressor is converted into heat. Without energy recovery, this costly thermal energy vanishes into the atmosphere via the cooling system and radiation. A properly designed heat recovery unit can recover anywhere from 50-94% of this available thermal energy (as low-grade heat) to heat air or water (up to 90°C).

Pre-heated water can be used in the application process to reduce the use of traditional energy sources, reducing your carbon footprint and giving you valuable savings. Most common uses include process heating, space heating and water heating.

OPTIMIZER4.0

www.atlascopco.co.uk

AIRnet™ pipeworkActing as the vascular system of your manufacturing site, your compressed air system plays a vital role in your production processes. Delivering quality air exactly where you need it, at the right pressure and at the lowest possible cost, Atlas Copco‘s innovative AIRnet™ compressed air piping system complements your compressed air projects. The wide range of durable products, including both aluminium and stainless steel pipework, as well as Point of Use accessories, makes AIRnet a complete solution from source to production.

FULLY CUSTOMISABLEFixed to walls or ceilings, AIRnet’s range of fittings lets you custom-build a compressed air system to your specific production needs.

LEAKAGE-FREEAIRnet fittings are corrosion-free. They ensure a leakage-free installation and eliminate energy wastage.

MAXIMUM FLEXIBILITYQuick drops can be added at any time to create extra drop legs. As the connection is made from the side section, the risk of condensate pollutant is eliminated.

CONSTANT AIR QUALITYAIRnet delivers constant quality air from point of generation to the various points of use, protecting downstream equipment and manufacturing processes.

EASY IDENTIFICATIONIn compliance with most industrial standards, AIRnet pipes are coated as standard in blue or green or grey for simple network identification.

LOW PRESSURE DROPThe clever design, with full diameter and inside fin guides, eliminates air flow restriction and guarantees the lowest possible pressure drop.

STAINLESS STEEL PIPES• No corrosion, leak resistant and 10 year guarantee• Press fit system ensures fast installation with minimal tools• No welding, no threading: just push & press• Silicone free system• FKM Seal (approved by all international regulating bodies for pharmaceutical,

food & beverages)• Can be used for clean room applications (316 L)

POINT OF USE ACCESSORIESDesigned and manufactured in accordance with the highest standards• One stop solution for your entire compressed air system• Relevant certificates and approvals• Available ex-stock

Control Gear LtdTreforest Industrial Estate, Heol GroeswenPontypridd, Mid Glamorgan CF37 5YFT: 01443 843126 F: 01443 841821

www.controlgear.netatlas-copco@control-gear.com