Wilderness Mountain Water Boosts Production and Cuts Energy Use with ELGi Oil-Free Compressor
From a historic artesian well in Virginia, Wilderness Mountain Water Company (Wilderness) has produced hundreds of millions of cans of its award-winning natural water over the past three years. A critical driver behind this success has been the installation of a single ELGi AB55 oil-free air compressor, which has transformed both the efficiency and sustainability of its operations.
Dramatic Energy and Cost Savings
By replacing its previous compressed air system with the ELGi AB55, Wilderness reduced its energy consumption by approximately 50%, cutting usage from 44 kWh to just 24 kWh per 100 CFM. This improvement has translated to nearly $5,000 in monthly utility savings, while the company’s canned water output increased by 150%.
Mike Stokes, Chief Operating Officer at Wilderness, emphasized how the compressor has directly supported the company’s growth.
The savings weren’t just on paper,” said Stokes. “We saw immediate results in our bottom line and 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 reinvested directly into expansion.”
A Partnered Approach to Efficiency
To achieve these results, Wilderness collaborated with Atlantic Compressors, an authorized ELGi distributor, to assess its site and conduct a comprehensive energy audit before installation. The findings guided the integration of the ELGi AB55, designed specifically to deliver ISO Class 0 certified, 100% oil-free compressed air — a critical factor for maintaining product purity in food and beverage production.
Cleaner, Safer Air for Beverage Production
The ELGi AB55 uses pre-coated stainless-steel rotors and a closed water-cooling loop to ensure long-term reliability and contaminant-free performance. Unlike oil-flooded compressors that rely on filters to remove oil particles, the AB55’s oil-free design ensures there is zero risk of contamination in the compressed air.
For a premium beverage company like Wilderness, clean compressed air is a non-negotiable standard. The air is in direct contact with the product at multiple stages of production, including:
- Pressurizing carbonators and filler bowls (around 45 PSI)
- Purging cans with sterile air before filling
- Operating pneumatic valves, seamers, and filler controls
- Driving de-palletizers that unload empty cans
- Powering tray formers and carton packers
- Blowing moisture off cans before labeling with air knives
- Running palletizers that stage finished products for shipment
The air comes into direct contact with the product, so sterile air is essential,” added Stokes. “An oil-free compressor is non-negotiable for us.”
Empowering Sustainable Growth
By investing in advanced oil-free air compression technology, Wilderness has achieved a rare balance of product purity, operational efficiency, and environmental responsibility. The measurable savings in energy and maintenance costs have allowed the company to reinvest in scaling operations — demonstrating how modern compressor technology can directly fuel growth in the beverage sector.
As Wilderness continues to expand production from its historic Virginia well, its partnership with ELGi and Atlantic Compressors serves as a model for how innovative engineering and sustainable air systems can transform manufacturing performance in the food and beverage industry.
