Wilderness Mountain Water Company Halves Energy Use and Boosts Canning Output by 150% with ELGi Compressor
From a historic flowing artesian well in the foothills of Virginia, Wilderness Mountain Water Company (Wilderness) has established itself as a leading producer of premium canned water. Over the past three years, the company has filled and distributed hundreds of millions of cans of its award-winning artesian water, delivering naturally pure hydration to consumers who value sustainability and taste.
Now, through a partnership with ELGi Compressors USA, Wilderness has achieved a remarkable leap in both energy efficiency and production output—cutting energy use by approximately 50% and increasing canning capacity by 150%. This transformation, driven by the installation of a single ELGi AB55 oil-free air compressor, underscores how the right air system can redefine performance and profitability for beverage manufacturers.
Transformative Efficiency Gains
Prior to installing the ELGi AB55, Wilderness’s operations were constrained by high energy costs and limited capacity. Compressed air is a vital part of beverage processing, powering everything from can purging to palletizing, but it can also be one of the largest energy consumers in a production facility.
When the new ELGi AB55 compressor was commissioned, the impact was immediate. Energy consumption dropped from 44 kWh to 24 kWh per 100 CFM, translating to a 50% reduction in power usage. The result was nearly $5,000 in monthly utility savings, freeing up capital that the company could reinvest into growth initiatives. At the same time, canning throughput soared by 150%, dramatically improving output without increasing overhead.
According to Mike Stokes, Chief Operating Officer at Wilderness, the improvement went far beyond efficiency metrics.
The savings weren’t just on paper,” Stokes explained. “We saw the results immediately in our bottom line and in our production capacity. That kind of growth just isn’t possible without the right air system behind it. The technology has been a game-changer—we’re saving thousands each month that we’ve been able to reinvest directly into expansion.
Oil-Free Technology: Clean Air for Pure Water
Wilderness’s commitment to quality and purity made the switch to oil-free air compression an obvious choice. Working closely with Atlantic Compressors, an authorized ELGi distributor, the company conducted a comprehensive site assessment and energy audit before installation to ensure the new system would meet all performance and sustainability goals.
The ELGi AB55 oil-free air compressor delivers ISO Class 0 certified air—meaning it produces 100% oil-free, microbiologically clean compressed air. Its innovative design incorporates pre-coated stainless-steel rotors and a closed water-cooling loop, ensuring maximum reliability and purity without the need for lubricating oil.
Unlike traditional oil-flooded compressors, which rely on filtration systems to remove contaminants, the ELGi oil-free unit eliminates the risk of oil contamination altogether. For Wilderness, this distinction is crucial, since compressed air comes into direct contact with the product at multiple stages of the canning process.
The air comes into direct contact with the water and packaging,” Stokes noted. “Sterile, oil-free air isn’t optional—it’s essential for maintaining the purity and quality of our artesian water. With the ELGi compressor, we have complete confidence that every can meets our high standards.
Compressed Air: The Invisible Power Behind Beverage Production
While consumers may focus on what’s inside the can, the behind-the-scenes technology that enables beverage packaging is equally important. At Wilderness’s facility, compressed air plays a critical role in nearly every production step:
- Pressurizing carbonators and filler bowls to maintain consistent flow rates (typically around 45 PSI).
- Purging cans with sterile air prior to filling, ensuring zero contamination.
- Operating pneumatic valves, seamers, and filler controls, which maintain precision in the filling process.
- Driving de-palletizers that unload empty cans and position them for filling.
- Powering tray formers and carton packers for efficient packaging operations.
- Blowing moisture off cans using air knives before labeling.
- Running palletizers that stage finished products for shipping and distribution.
Each of these operations depends on reliable, clean, and stable air pressure. Even a brief interruption or contamination event could cause costly downtime or product loss. The ELGi oil-free system ensures continuous, sterile airflow while maintaining efficiency and consistency across all stages of production.
Partnership for Progress: Working with Atlantic Compressors
The successful implementation of the new compressor system was made possible through collaboration with Atlantic Compressors, a regional ELGi partner known for its expertise in air system design and energy optimization. Before installation, Atlantic’s technical team conducted a comprehensive audit to evaluate Wilderness’s existing infrastructure, airflow requirements, and energy profile.
This detailed assessment guided the configuration of the new ELGi system, ensuring that it would deliver optimal performance while aligning with Wilderness’s sustainability and operational targets. The distributor’s involvement extended beyond installation to include training, performance monitoring, and maintenance planning, helping Wilderness maximize uptime and long-term equipment reliability.
Investing in Sustainable Growth
Encouraged by the dramatic performance gains of its first ELGi compressor, Wilderness is now planning for the next stage of its modernization journey. The company intends to install two additional ELGi compressors, which will be networked with smart control systems to balance load demand, monitor efficiency in real time, and provide predictive maintenance insights.
This integrated approach will not only support higher production volumes but also reinforce Wilderness’s sustainability leadership within the beverage industry. By combining renewable water sourcing, recyclable aluminum packaging, and clean compression technology, Wilderness demonstrates how environmentally responsible practices can coexist with commercial success.
Sustainability is at the core of everything we do,” Stokes emphasized. “Our artesian well provides naturally renewable water, and our aluminum cans are infinitely recyclable. Partnering with ELGi helps us extend that same philosophy to our operations—reducing energy consumption and emissions while scaling our business responsibly.
About Wilderness Mountain Water Company
Founded near a historic artesian well in Virginia, Wilderness Mountain Water Company produces premium canned water known for its natural purity and balanced mineral composition. The company is dedicated to sustainable sourcing, recyclable packaging, and energy-efficient production, delivering clean hydration to environmentally conscious consumers across North America.
About ELGi Compressors USA
ELGi Compressors USA is a subsidiary of ELGi Equipments Limited, one of the world’s leading air compressor manufacturers with a presence in over 120 countries. ELGi designs and builds innovative, reliable, and energy-efficient compressed air solutions for industries ranging from manufacturing and food processing to automotive and pharmaceuticals. Its oil-free compressors are ISO Class 0 certified, ensuring contamination-free air for the most demanding applications.
This rewritten version enhances structure and flow, provides professional polish, and expands explanations and context to achieve about 880–900 words.
Would you like me to extend it slightly (to around 1,000 words) with a closing section highlighting ELGi’s broader sustainability and industrial impact
Source link:https://www.businesswire.com/
