Tips to increase compressor installation efficiency

Compressed air accounts for a significant part of total energy costs for industrial manufacturers - typically about 12% and maybe as high as 40% in some facilities. This means that finding innovative ways (no matter how small) to increase compressed air efficiency can amount to big savings over the long run. Items like leak elimination, air audits, reduced pressure bands, and reducing unloaded running hours are some of the most popular ways to decrease energy usage – but there are many other actions that you can take to reduce your costs and make sure your compressor system is running as efficiently as possible.

Choosing the wrong size air compressor for your facility can lead to production issues and increased costs due to wasted energy. When choosing the right type of compressor, consider these questions:

• What is the application?
• How much air flow does my facility/workshop use?
• What is the minimum pressure needed within the facility?
• Do I need clean, dry air?
• How many hours per year does my compressor operate?
• How many shifts do I run per day?
• Is there fluctuation in flow demand between shifts?
• Are there any plans for future expansion?

Once you have the answers to the above, make sure that you select your compressor based not only on initial cost, but on the lowest total lifecycle costs.

Air compressors are long term investments that will play a significant role in your business for years to come. The average factory changes air compressors every 7-10 years, meaning that the initial capital expenditure is only a fraction of how much your compressor will cost you in total. 70% or more of your air compressor’s lifecycle cost will come down to its energy usage.

Switching or updating your compressed air installation to the latest technology can reduce energy consumption by up to a quarter. If you have an old or inefficient compressor, the cost to replace it with a new compressor is often less than the current running costs. A modern air compressor with the latest controllers and energy efficient motors will contribute to your bottom line from day one.

You can also think about upgrading certain aspects of your compressor. Reach out to your compressed air provider to discuss the possibility of replacing major components of your compressor with new, more efficient components. For example, upgrading your compressor with the latest type of electronic controller will allow you to take advantage of the most advanced compressor control management, reduced unloaded running and higher efficiency.

Many applications in the food and beverage, electronics, oil & gas, automotive, textile, and pharmaceutical industries require oil-free air to guarantee product integrity and quality (often specified as Class 0). Oil-free compressed air technology will help to avoid expensive filter replacements, cut the cost of oil condensate treatment and reduce energy loss from pressure drop in filters.

If you have a very large-scale application, you can also consider a centrifugal compressor, given that these offer energy efficiency in process air or in bulk air applications presenting a flat load; they're also ideal for providing a baseline flow in mixed installations with VSD screw compressors.

Most production processes require different levels of demand in different periods, which may mean that the compressor is running off-load or idle (not producing any compressed air) for long periods of time. Great savings can be made if a fixed speed compressor can be replaced by a variable speed drive unit as it only produces compressed air as and when required. This also minimises offload running of the compressor, which is known to waste energy. A VSD compressor saves an average 35% energy and a VSD+ unit can save as much as 50% compared to a fixed speed unit, even at full load.

The best way of taking care of your compressed air availability is by taking the best care of your compressed air equipment. This means investing in regular preventative maintenance, which will sustain the efficiency that you have gained by purchasing a new compressor or improve the performance of an older unit. Whether you prefer to purchase spare parts only and perform maintenance in-house, sign up to a planned maintenance program at pre-determined intervals from the manufacturer or approved distributor, or choose a total responsibility package that covers breakdowns and leaves no room for surprises, the main thing to remember is that reduced compressor performance is inevitable as the machine gets older. Regular servicing, using OEM genuine parts is more critical in the Middle East region where the climate is humid and dusty, will improve your equipment uptime and energy efficiency: the opposite could lead to more downtime, increased energy consumption and potentially a costly breakdown.

Lastly, gather some data! Data monitoring such as SMARTLINK data box gives you remote insight in your air system. It enables you to detect problems, identify potential improvements and even follow up on actual savings!

Want to learn more about the ways to save energy, download the guide: