Rotable Repairs needed more than new equipment, their existing compressed air and nitrogen systems were limiting production, reliability, and growth.
Air Energy delivered a fully integrated solution, combining duty/standby compressors, nitrogen generation, high-pressure boosting, and advanced air treatment. The system was engineered for continuous operation, consistent purity, and scalability in a compliance-critical aviation environment.
Despite power and installation constraints, the entire project was delivered with zero downtime.
The result: increased throughput, full operational resilience, improved control, and a significantly lower energy footprint.
Rotable Repairs is a specialist aircraft component repair station, delivering inspection, overhaul, and refurbishment of wheels, brakes, and hydraulic systems for multiple airlines.
As demand increased, their existing compressed air and nitrogen infrastructure became a constraint:
• Insufficient capacity to support production growth
• Ageing equipment impacting reliability
• Limited redundancy introducing operational risk
• Inefficient systems increasing energy consumption
In a compliance-critical aviation environment, these limitations were not just operational — they posed a risk to throughput, consistency, and long-term scalability. Rotable Repairs needed more than replacement equipment. They needed a robust, engineered system that could scale with their business.
Air Energy designed and delivered a fully integrated compressed air and nitrogen system, engineered for continuous operation, pressure stability, and operational resilience.
Compressed Air Generation
2 × CompAir L45RS rotary screw compressors configured in a duty/standby arrangement, providing efficient base load operation with automatic failover to maintain uninterrupted supply.
Air Treatment & Drying
CompAir CD160F refrigeration dryer for bulk moisture removal
Walker Filtration Alpha coalescing filters for oil and particulate removal
Twin desiccant dryers (PD0300 & PD0056G) delivering low dew point air for critical applications
This staged approach ensures consistent air quality across varying load conditions.
Air Receiver & Condensate Management
Integrated air receiver with automatic drain and oil/water separation system, ensuring stable pressure buffering and compliant condensate handling.
Nitrogen Generation
2 × CompAir CN2047 nitrogen generators configured in lead/standby operation, providing on-demand nitrogen with built-in redundancy to support uninterrupted aircraft maintenance processes.
High-Pressure Boosting
Reavell 5407NB open-frame booster and Reavell 5407 N2 enclosed nitrogen booster.
Designed to deliver high-pressure air and nitrogen for specialist applications, with separation between general and nitrogen boosting to maintain system integrity. The system was designed to ensure zero single points of failure across both compressed air and nitrogen supplied system that could scale with their business.
This was not a like-for-like replacement. The system was designed to:
• Ensure continuous production capability with full redundancy. Deliver consistent air and nitrogen purity for aviation standards
• Provide stable pressure and flow under peak demand
Enable future expansion without system redesign
The project was phased strategically:
• Nitrogen infrastructure upgrade securing the critical production dependency first
• Compressed air system replacement aligning capacity with operational demand
The installation presented real-world engineering challenges:
Power limitations:
→ Existing supply could not support system load
→ Temporary generation deployed to maintain stability
Handling and installation constraints:
→ Equipment weight exceeded on-site lifting capacity
→ Specialist handling methods used to position units safely
Despite this, Air Energy maintained a strict operational priority: Zero disruption to production.
The result is a high-performance, futureproofed system aligned to Rotable Repairs’ growth trajectory.
Measurable Impact:
• Zero downtime during a multi-phase, multi-year project
• Increased production capacity and throughput
• Full system redundancy → operational resilience
• Improved process control and consistency
• Reduced energy consumption and lower carbon footprint.
The system now supports uninterrupted high-pressure cycles with no flow interruption, validating both design and execution.
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 confident that our partnership with Air Energy will result in optimised operations and long-term value for our organisation.
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.
This project reflects a core Air Energy engineering principle: Performance comes from system design, not individual components. By engineering the full compressed air and nitrogen ecosystem, Rotable Repairs now operates with greater confidence in uptime, control over production variables and infrastructure that supports long-term growth
If your compressed air or nitrogen system is limiting performance, we’ll help you quantify the impact and engineer a solution around it.
Call us 01992 238 314
Or email us on [email protected]
We specify and supply integrated compressed air, vacuum and nitrogen systems tailored to your operational requirements:
> Fixed & variable speed compressors
> Air treatment & filtration systems
> Nitrogen generation
> Full system specification & sizing
> Energy efficiency optimisation
Complete mechanical and electrical installation delivered safely, efficiently and with minimal disruption to your site:
> Pipework design & installation
> Control integration
> Commissioning & performance testing
> Turnkey project delivery
> Compliance documentation
Proactive servicing and diagnostics to maximise uptime, efficiency and system lifespan. Our focus is long-term system reliability, not reactive repair:
> Planned preventative maintenance
> 24/7 emergency breakdown support
> Breathing air quality testing
> Leak detection & energy audits
> Genuine parts & consumables
Practical guidance on reliability, efficiency and compliance for compressed air, vacuum and nitrogen systems.
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