LAPP Insulators Cut Costs with Air-Operated Double Diaphragm Pumps


LAPP Insulators is a leading manufacturer and supplier of high-voltage insulators, which are used to support transmission lines on steel towers. The company is based out of LeRoy, New York and supplies insulators to more than 70 countries.


LAPP Insulators sought to reduce operational costs by around 20 percent. The manufacturing operations were running 19 air-operated double diaphragm (AODD) pumps at roughly 1,450 scfm of compressed air at an annual rate of $37,000.


To better understand consumption of compressed air and cost per kWh, Stark Tech performed an Air Loss Study to identify efficiency opportunities.

The recommendation was to replace / retrofit four (4) 2” AODD pumps and fourteen (14) 3” AODD pumps with Pro-Flo SHIFT air motors by Wilden Pumps. The SHIFT Series is the industry’s premier air distribution system used to increase productivity, reduce energy and air consumption, and simplify maintenance operations.

The design conserves energy and maximizes meantime between repairs for the AODD pumps. With this solution, LAPP qualified for the area’s electric utility Energy Reduction Incentive Program, which awards rebates for energy-efficient improvements.


Today, LAPP Insulators is seeing a 30% reduction in compressed air for their pumps, resulting in a reduction in compressor usage and operations and maintenance expenditures. The new, state-of-the-art pumps are also showing less unscheduled downtime and a reduction in manhours spent repairing pumps in the manufacturing plant.

The energy cost savings for compressor operations is approximately 30% or $11,000 annually.