Aircraft Repair Station Adopts Future-Proof System

Rotable Repairs, established in 2002, specialises in the comprehensive testing, inspection, repair, and overhaul of various aircraft components, including wheels, brakes, and hydraulic systems. As the company expanded, its existing compressors and nitrogen generators could no longer meet the growing demands. Seeking to maintain its reputation for excellence, Rotable Repairs turned to Air Energy to upgrade its aging and inefficient equipment.

Overview

Customer
Rotable Repairs
Location
Southend-on-Sea, Essex
Specialism
Aircraft repair station
Application
Complete air and nitrogen set-up for the refurbishment and repair of aircraft tyres for multiple airlines
Customer Benefits
Increased productivity, reliability, control over production, and a significantly lower carbon footprint
New Machinery Installed:

CompAir L45RS Compressor x2

CompAir Cn2047 Nitrogen Generator x2

CompAir Cd160F Refrigeration Dryer

Walker Filtration Alpha Coalescing Filter Set

Walker Filtration PD0300 and PD0056G Desiccant Dryers

Reavell 5407NB Booster (Open frame)

Reavell 5407 N2 Booster (Enclosed)

The Project

The project was split into two stages, beginning with the replacement of nitrogen generators, which are critical for producing the high-purity nitrogen used to inflate aircraft tyres. Two generators were installed, allowing for both lead and standby operations. This set-up ensured continuous production capability, even during peak periods.

Following the successful installation and testing of the nitrogen generators, Air Energy moved on to replacing the compressors. These new compressors were vital to maintaining consistent production levels and ensuring that the facility could meet its operational goals.

Any Problems?

During the project, a few challenges arose:

Power supply issues: The existing power supply was insufficient to handle the new equipment’s demands. To overcome this, a generator was installed to ensure a stable and reliable power source.
Installation challenges: The compressors’ significant weight exceeded the capacity of the available forklifts. Air Energy used a pump truck and specialised lifting equipment to safely position the units.

A High-Quality Result

Despite these challenges, Rotable Repairs experienced no downtime throughout the three-year project. The culmination of the work was the booster running a full cycle without any flow interruptions — a testament to the project’s success.

Mark Asker, Managing Director at Air Energy, reflected on the project: “A customer relationship had been built on trust between our companies over a lengthy period. Air Energy delivered on its promises and made sure we were always on hand to help with any issues. From our point of view, it is extremely satisfying that they now have a reliable and futureproofed system.”

Bryan Croft, Managing Director of Rotable Repairs, shared his satisfaction: “We chose Air Energy due to their exceptional reputation for delivering high quality products and excellent service. Their expertise and commitment to customer satisfaction were evident throughout the project, providing tailored solutions and valuable insights. We are confidents that our partnership with Air Energy will result in optimised operations and long-term value for our organisation.”

For more information about our products and services, email sales@airenergyuk.com or call 01992 586 666.