Stone Fabrication
Huntley, Illinois
Old World Stone needed a reliable and efficient compressed air system to power their growing operations while keeping energy costs in check. Fluid-Aire Dynamics delivered a tailored solution to support their expansion and ensure long-term success. A dual-compressor system with VSD motors and an efficient air distribution system from Unipipe have enabled them to ramp up production while keeping energy costs low.
“Fluid-Aire Dynamics has been with us since the beginning. Whatever we need, we know we can reach out to them, and it will be taken care of. Having reliable compressed air equipment and service has supported our growth over the years,” — Mike Gliszczynski, General Manager, Old World Stone.
The Challenge: Supporting Growth While Reducing Compressed Air Costs
Old World Stone fabricates and installs stone and quartz products for both residential and commercial buildings. They work directly with architects and builders to design and deliver stunning custom-cut countertops and surfaces for kitchens, baths and more. In 2022, they moved into a new state-of-the-art fabrication shop in Huntley, Illinois, to accommodate the growth of their business.
The 36,000-square-foot shop houses five CNCs, three water jets, a bridge saw and a variety of manual tools for custom work, all powered by compressed air. They needed more capacity to run all the production equipment in the new space, in addition to a new distribution system. At the same time, they wanted to find a way to reduce energy costs for compressed air. 
The Solution: VSD Air Compressors and an Efficient Aluminum Piping System
Fluid-Aire Dynamics has supported Old World Stone for their compressed air needs for more than 15 years, including new equipment to support growth as well as preventative maintenance and repair services to keep their systems in top condition. So, it was natural for them to reach out to us when they were making plans for their new facility.
We installed two 40HP Variable Speed Drive (VSD) rotary screw compressors from PneuTech, which can each deliver up to 110 cubic feet per minute (CFM) of air at 100 PSI. The VSD motors ramp up or down in response to actual compressed air demand, which saves significant energy compared to their older fixed-speed compressor. The compressors run in series; as demand rises beyond what one compressor can deliver, the second compressor automatically kicks in. The system also includes two refrigerated dryers, inline filtration and wet and dry air tanks.
The air distribution system has 10+ drops to deliver air to the various machines. There was some existing black iron pipe in the building that was still in good condition. We were able to tie into the existing lines to save some upfront costs. The new part of the distribution system is a modern aluminum piping system from Unipipe. The new Unipipe distribution system not only looks great but was fast and easy to install and will deliver reliable, leak-free performance. The system is warranted for 20 years.
Results: Substantial Energy Savings and a Reliable, Efficient Compressed Air System
The VSD air compressors have cut their energy bills for compressed air production by more than 25%. Mike Gliszczynski, the General Manager, says, “They’ve basically paid for themselves.” Even better, Fluid-Air Dynamics helped them apply for and secure energy incentives from ComEd, their power company, that helped pay for the upgrade. Fluid-Aire made the process painless, taking care of 99% of the paperwork, so all they had to do was sign.
As Old World Stone prepares for their next stage of growth, Fluid-Aire Dynamics will be there to support them. They continue to rely on FAD for ongoing maintenance and support. Mike says, “In this industry, compressed air is crucial to our day-to-day operation. If the machines aren’t running, we’re not making any money. We’ve had a very positive relationship with Fluid-Aire Dynamics, and we plan to continue working with them hopefully for many years to come”.
