Case study: Kaeser quenches E’stel Water’s thirst for state-of-the-art high pressure compressed air technology

Growing product demand recently led premium alkaline water bottler E’stel Water to invest in a tailored and state-of-the-art Kaeser compressed air system, complete with a turn-key DN series booster to meet the high compressed air pressure requirements of their new PET blow molding machine.

E’stel Water is a premium alkaline water that is sourced and bottled in Nelson, New Zealand. The artesian water comes from the snow-capped mountains of New Zealand and travels underground where it filters through various minerals. 895 metres below the surface of the Waimea Plains in Nelson, E’stel then extract this high alkaline water, before transporting it to a modern purpose built bottling plant, where it is; bottled, capped, labelled and packed ready for global distribution.

The uniquely E’stel shaped plastic bottles that this high alkaline water is packaged in, are manufactured on site using a PET blow molding machine. As demand for E’stel Water has steadily grown since the company was established just 3 years ago, so has the requirements of the bottling plant. This led to the recent investment into a much larger capacity PET blow molding machine. Responsible for manufacturing the water bottles, the PET blow molding machine relies on an efficient supply of compressed air. At certain points within the process, compressed air needs to be pressurised up to 40 bar.

This inflates the soft PET (polyethylene terephthalate) plastic into a mold cavity which takes the desired shape and size of the water bottles. With a standard industrial compressor reaching around a 10 bar pressure, a booster compressor is therefore additionally required at those points in the production process where this high pressure compressed air is required, to literally boost, or increase, the air pressure up to the desired level of - in this case - 40 bar. The new PET blow molding machine at E’stel is able to blow a staggering 11,000 bottles per hour (BPH).

As it is a much larger system than what the company had previously, a new compressed air system was therefore required to meet this increased demand for compressed air. Wayne Herring, Co-Founder and Director of E’stel Water, called upon existing and local compressed air specialist – and authorised Kaeser partner - PSL Total Air to present a suitable solution. In order to meet both the low and high pressure compressed air demand of the new PET blow molding machine, PSL recommended and subsequently installed a complete compressed air system that included a Kaeser CSD 105 rotary screw compressor and a Kaeser DN 22 series booster.

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Kaeser Compressors manufactures a wide range of compressors and associated auxiliary equipment that meet the varying requirements of a diverse range of industries and applications. One of the world’s largest manufacturers of rotary screw compressors, Kaeser Compressors is represented globally in over 100 countries through a dedicated network of branches, subsidiary companies and authorised partners. Kaeser Compressors Australia provides comprehensive sales and service from its 30,000 ft2 purpose built factory in Dandenong, Victoria alongside an extensive network of sales and service centres and authorised partners that cover Australia, New Zealand and New Caledonia.