A world leader in the luxury crystal ware market, Waterford Crystal, modernized operations with ELGi's EG Series compressors.

The world renowned Irish manufacturer of premium crystal glassware and gifts, Waterford Crystal, founded in the 18th century, chose an ELGi EG Series' oil-lubricated screw air compressor, to enhance the energy efficiency of its compressed air system and, in turn, enhance high-precision engraving operations.

Never fading outlook of luxury ware

Crystal is composed of silica (sand), lead oxide, and soda and is known for being durable. Traditional crystal manufacturing involves heating a mixture of high-quality sand, lead oxide, and other ingredients to extremely high temperatures to create a molten glass mixture. The molten glass is then shaped and cut using various tools and techniques to produce the desired shape and design.

The artistry in each piece of crystal is admired, even in the age of sound bites. Even the most cutting-edge designs draw on the rich history and talents of its artists. This admiration is expected to grow in the 21st century, just as it has in the past. The luxury crystal ware segment has expanded into bar and drinkware, tableware, decoration, lighting, jewellery, and accessories. The rising popularity of home improvements, rising per capita disposable income, and changing lifestyles are some of the factors driving the industry's growth.

The global luxury crystal market has been witnessing a surge because of increased demand for luxury consumer goods. The countries where the luxury crystal ware market has seen sizeable growth are North America, Europe, Asia Pacific, Latin America, the Middle East, and Africa.

In recent years, the luxury crystal ware market has faced some challenges, on account of changing consumer preferences, increased competition from other luxury goods categories, and concerns over the use of lead in some crystal products. However, many luxury crystal ware manufacturers have responded by introducing new designs, materials, and manufacturing techniques, and by expanding their offerings to appeal to a wider range of customers.

The market size for luxury crystal ware was estimated at USD 5603.92 million globally in 2022 and is projected to grow at a CAGR of 6.62 percent to reach USD 8230.33 million by 2028. This unprecedented growth has driven crystal ware manufacturers to explore the market by adopting mergers and acquisitions, expansions, investments, new service launches, and collaborations as their preferred strategies. It has also steered them towards implementing technological innovations to enhance production efficiency and strengthen their market position.

Some of the leading luxury crystal manufacturers have shifted their attention to environmentally friendly practices and created a new crystal formula that will eventually replace lead oxide in the current formula with barium oxide. This would allow crystals to be made in a more sustainable way.

The air of accuracy and efficiency

Waterford Crystal is a renowned crystal ware manufacturer specializing in fine/luxury cut glass. With a vision to create the finest quality crystal for drinking vessels and objects of beauty for home, Waterford Crystal was founded by Penrose Brothers in 1783. Since then, it has stood for the highest calibre of craftsmanship and quality. Waterford Crystal—established in the Irish city of Waterford—symbolizes Irish culture. The company's offerings go beyond traditional stemware and classic interior pieces to embrace the contemporary luxury lifestyle experience. Its offerings include stemware and barware, fine chinaware and flatware, vases, bowls and centerpieces, collectibles, lighting, chandeliers, paperweights, holiday ornaments, and gifts.

Waterford Crystal has been used to create custom pieces for heads of state, celebrities, and other high-profile individuals, and its products are sold in luxury department stores and specialty shops around the world. The brand is now owned by the Fiskars Corporation, a Finnish company that produces a range of high-quality consumer products.

Finding the best alternative

Waterford Crystal has been the epitome of Irish heritage for decades. The esteemed factory has been manufacturing one of the world's most luxurious crystalware. Luxury crystal manufacturing requires precision and accuracy, which is achieved using industrial machinery and high-precision tools. These tools are operated using compressed air, which helps in achieving the accuracy required for the cutting and engraving processes.

To maintain the purity of color, quality, and aesthetic appeal of its crystal ware offerings, Waterford attaches high importance to its compressed air system. Thus, Waterford Crystal was looking at replacing its old compressor, given that the operation of a significant percentage of its industrial gear and high-precision engraving tools depended on the efficient functioning of these compressors.

The challenge was to select an energy-efficient and cost-effective compressor that could enhance operational reliability and profitability. Also, since Waterford belongs to an era of sustainability-driven business, it was looking at adopting a solution that can improve its overall sustainability imperative, creating smaller environmental footprints.

Transforming the overall efficiency with an air audit

Airtec Compressors Ltd., ELGi's Channel Partner in Cork, Ireland, was commissioned to install a solution. After an audit of Waterford's old compressors, Airtec Compressors recommended the installation of the ELGi EG22V. Based on estimates, the ELGi compressor promised an energy reduction leading to a 2.5-year payback, equating to an initial purchase cost repaid through energy savings within the 2.5 years of usage.

Waterford chose the ELGi EG series on account of its:

Market leading 10-year airend warranty
Performance at extreme temperatures: EG Series compressors can perform across extreme temperatures, ranging from cold to hot and from dry to extremely humid conditions
Highly efficient airend: ELGi's airends are equipped with in-house developed η-V profile rotors (with 4/5 lobe combination) designed to run at optimum speeds. This unique design reduces pressure losses and increases efficiencies
Lower maintenance cost

According to a spokesperson in Waterford, "The ELGi EG22V is our lead compressor and has been operating seamlessly at our factory for over a year now without an issue. Since installing the EG22V, we have seen a considerable reduction in our energy consumption.

This is relative to the performance of our older compressor, which incurred higher electricity costs. However, the EG22V has given us a payback in less than two years."

The adoption of the ELGi EG series offered Waterford the following business benefits:

Enhanced efficiency: The ELGi EG compressors are designed to enhance production efficiency, which makes them ideal for Waterford's manufacturing process. These compressors helped Waterford realize unparalleled performance.
Quality products: The continuous supply of high-quality compressed air enhanced the efficiency of high-precision tools used by Waterford for manufacturing crystals, maintaining the purity of their color and quality.
Reduced costs: The reduced operational costs owing to reduced energy consumption allows Waterford a payback on investment in less than two years.

Overall, the adoption of the ELGi EG series by Waterford not only optimized production efficiency and product quality but also delivered significant cost savings, demonstrating the substantial value that this compressed air system brings to Waterford's manufacturing operations.

A Winning Collaboration

Airtec Compressors has been working with ELGi since 2020, recognizing the brand's qualities and the way the company collaborates with its channel partners. It recognizes Elgi Equipments Limited as a leading manufacturer of air compressors with a wide range of cutting-edge compressed air systems. This recognition is built upon ELGi's commitment to delivering cutting-edge technology and solutions that meet the diverse needs of compressed air industries worldwide. Through this partnership, Airtec Compressors has access to ELGi's superior products and expertise, enabling them to provide their customers with reliable and efficient compressed air solutions that drive success and innovation in their operations.

"At ELGi, our vision is to be 'Always Better,'" said Terry McGuire, Regional Manager UK & Ireland, at ELGi. He added, "Our new EG Series embodies this approach with innovative technology options that help our customers be more efficient, lower their life cycle costs, and reduce their environmental footprint. The EG Series stands out for its patented technologies, high efficiency, and 10-year market-leading warranty on the airend."

Given the duration and nature of this collaboration between Airtec Compressors and ELGi, Waterford values the recommendations made by Airtec Compressors. The former's expertise, knowledge, and recommendations have improved the efficiency of Waterford Crystal’s compressed air systems.

With ELGi's EG Series compressor, Waterford Crystal has been able to produce high-quality products with greater accuracy and precision. Sarah Murray Walsh, from Airtec Compressors, said, "We are a dedicated 24/7 company that prides ourselves on always delivering on the promises we make to our very long-term and loyal client base. We maintain this promise through a dedicated service/engineering team, a dedicated and customer-driven sales team, a health and safety team, and a focused air quality team. These teams serve the compressed air needs of clients across Ireland."

Compression that delivers right

A collaboration with ELGi enabled Waterford to achieve its short- and long-term efficiency targets. It was able to meet its overarching productivity, energy efficiency, quality, and reliability targets. High-quality compressed air, backed by decreased pressure losses and higher energy efficiencies, translated into high energy savings and a lowered carbon footprint. Briefly, ELGi's screw air compressors helped Waterford Crystal to align its production process with economic, environmental, and social sustainability objectives.