Wilderness Mountain Water Company Slashes Energy Use by Half and Boosts Canned Water Output by 150% with ELGi Oil-Free Compressor
From a historic flowing artesian well in Virginia, Wilderness Mountain Water Company (Wilderness) has made a name for itself as one of the leading producers of premium canned water in the United States. Over the past three years, the company has produced hundreds of millions of cans of its award-winning artesian water, recognized for its purity and natural mineral balance. But behind the clean, crisp taste and the brand’s growing success lies an often-overlooked factor — the efficiency and reliability of its compressed air systems.
Recently, Wilderness underwent a major upgrade in its production facility that completely transformed its operations. By commissioning an ELGi AB55 oil-free air compressor, the company not only achieved a 50% reduction in energy use but also realized a 150% increase in production output. The new system has delivered significant operational benefits, including reduced utility costs, improved process reliability, and enhanced product quality.
Cutting Energy Use in Half
Compressed air is a critical utility for food and beverage manufacturing, but it’s also one of the most energy-intensive. Prior to installing the ELGi system, Wilderness’s air compression setup consumed about 44 kWh per 100 CFM of airflow. After commissioning the ELGi AB55 oil-free compressor, that figure dropped to 24 kWh per 100 CFM — representing nearly a 50% reduction in energy consumption.
This efficiency improvement translated directly into cost savings. According to Wilderness, the company is now saving approximately $5,000 every month in utility expenses. These savings are particularly meaningful in an industry where operational margins are tight, and every kilowatt-hour counts.
“The savings weren’t just on paper,” explained Mike Stokes, Chief Operating Officer at Wilderness. “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.”
Boosting Production Capacity by 150%
Alongside the dramatic reduction in energy costs, Wilderness’s production capacity grew by 150% following the installation. The increased output stemmed from the compressor’s reliability and consistent delivery of clean, oil-free air — a vital requirement for canning and packaging drinking water.
Before switching to ELGi, the company occasionally faced issues related to downtime and inconsistent air pressure. These small interruptions could lead to inefficiencies in can filling, sealing, and packaging processes. With the new compressor, Wilderness has achieved smoother, more stable production runs with minimal maintenance interruptions.
The result: faster production cycles, improved uptime, and enhanced overall equipment effectiveness (OEE) — all critical metrics for scaling operations efficiently and sustainably.
The Role of Compressed Air in Beverage Canning
In modern food and beverage production, compressed air serves as the invisible workhorse driving dozens of critical processes. At Wilderness, compressed air is used in virtually every stage of the canning and packaging process.
The company uses compressed air for:
- Pressurizing carbonators and filler bowls to around 45 PSI for precise filling.
- Purging cans with sterile air before filling to maintain purity.
- Operating pneumatic valves, seamers, and filler controls for accurate and hygienic operations.
- Driving de-palletizers that unload empty cans from pallets.
- Powering tray formers and carton packers that prepare packaging materials.
- Blowing moisture off cans with air knives before labeling to ensure adhesion.
- Running palletizers that stage finished products for shipment.
“The air comes into direct contact with the product, so sterile air is essential,” said Stokes. “An oil-free compressor is non-negotiable for us.”
Indeed, in the beverage industry, any contamination of compressed air can compromise product safety and integrity. For Wilderness, the choice of an oil-free system was about more than efficiency — it was a commitment to purity, quality, and brand trust.
Partnering with Experts for a Turnkey Solution
To implement the new system, Wilderness partnered with Atlantic Compressors, an authorized ELGi distributor. The process began with a comprehensive site assessment and energy audit to evaluate existing inefficiencies and identify opportunities for improvement.
Following the audit, Atlantic Compressors recommended the ELGi AB55, a robust oil-free air compressor that could meet Wilderness’s production demands while ensuring compliance with stringent food-grade air standards. The installation was carried out seamlessly, minimizing disruption to ongoing production.
“The collaboration with Atlantic Compressors was exceptional,” Stokes noted. “They understood our operational needs and guided us through every step — from the energy audit to installation and optimization. The result has exceeded our expectations.”
Why ELGi AB55 Stands Out
The ELGi AB55 is engineered specifically for industries where air purity is critical, such as food and beverage, pharmaceuticals, and electronics. It delivers ISO Class 0 certified air, ensuring 100% oil-free, microbiologically clean compressed air — a necessity for operations like Wilderness’s, where air directly contacts the final product.
Key features of the ELGi AB55 include:
- Pre-coated stainless-steel rotors, which provide superior corrosion resistance and long service life.
- A closed water-cooling loop for optimal heat management and stable performance.
- No oil used in compression, eliminating the risk of contamination and reducing maintenance costs.
- Quiet operation and a compact footprint, making it ideal for food-grade production environments.
Unlike oil-flooded compressors that depend on multiple filters to remove oil aerosols and vapors from the compressed air, oil-free compressors inherently eliminate the risk of oil contamination. This means cleaner air, fewer consumables, and lower long-term operational costs.
Sustainability and Quality Go Hand in Hand
For Wilderness, sustainability is not just a corporate buzzword — it’s a guiding principle that influences every decision. The company’s artesian well, located in Virginia’s pristine countryside, produces naturally filtered water that is packaged in fully recyclable aluminum cans. The shift to a high-efficiency, oil-free compressor aligns perfectly with Wilderness’s environmental goals, reducing its carbon footprint while enhancing product integrity.
By cutting electricity use nearly in half, the company has significantly reduced its CO₂ emissions, further reinforcing its commitment to sustainable production. These operational efficiencies have allowed Wilderness to expand responsibly — scaling output without increasing environmental impact.
Reinforcing Growth and Innovation
The success of the ELGi system has positioned Wilderness Mountain Water for continued growth in a competitive beverage market. The combination of energy efficiency, cost savings, and product quality assurance has created a strong foundation for expansion.
“The compressor upgrade wasn’t just a maintenance improvement — it was a strategic investment in our future,” Stokes emphasized. “We can now scale production with confidence, knowing that our systems are efficient, reliable, and compliant with the highest quality standards.”
As consumer demand for sustainable and pure water products continues to rise, Wilderness is well-equipped to meet that demand — powered by clean energy practices and advanced technology from ELGi.
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