September 1, 2025
Did you know that compressed air systems can consume up to 40% of a factory’s electricity bill? The good news: you can reduce this energy consumption by up to 30% by optimizing your system’s efficiency. Our Compressed Air Optimization Savings Calculator helps you estimate your potential energy and cost savings instantly.
Why use our compressed air savings calculator?
Our optimization potential savings calculator gives you an instant, first-pass estimate of potential energy and cost reductions in your compressed-air system. Just enter basic information about your installation, and you will immediately gain insights into your potential savings:
- Total installed compressor power (kW)
- Electricity price (€/kWh) Total
- Annual operating hours (h/year)
- Natural gas price (€/kWh)
The tool shows how much you can benefit from measures such as repairing leaks or installing a central controller, among other practical steps you can take to further improve your system’s efficiency. Below are some commonly used options.
Key areas to optimize for maximum savings
1. Tighten the pressure band with a central controller
A central controller can accurately regulate the system pressure based on multiple parameters and algorithms. Using smart algorithms, the central controller processes data from compressors, blowers, dryers, and filters and ensures that they work together efficiently. This results in the highest possible efficiency for the entire installation.
In addition, a central controller reduces pressure fluctuations and ensures much more stable outlet pressure for your application. By significantly reducing the pressure band, the central controller achieves considerable energy savings. For every 1 bar (14.5 psi) reduction in pressure, energy consumption decreases by 7%. Reducing the system pressure also reduces the impact of leaks. A 1 bar (14.5 psi) pressure reduction decreases the impact of air leaks by 13%.
2. Detect and repair compressed air leaks
In older compressed air systems, up to 20% of total compressed air consumption can be lost through leaks. A leak of just 1/8 inch can result to nearly 42 000 kWh of wasted energy annually. Repairing compressed air leaks is a highly effective way to save energy.
3. Turn compression heat into useful energy
Up to 94% of the electrical energy used for compression turns into heat, most of which is dissipated via the cooling system. A large part of this energy can be recovered and used as process heat. Since nearly 70% of all industrial processes use hot water or steam, energy recovery units can reduce both the fuel and maintenance costs of alternative equipment. By capturing compressor waste heat to produce hot water, you can typically reuse about 80% of the residual heat
4. Minimize power consumption by switching to new technologies
Installing the latest compressor controllers or electric motors makes your installation more efficient. Upgrading to new technologies can save up to 2% of your energy consumption.
Start saving today
Ready to take control of your energy costs? Use our compressed air savings calculator to discover your potential savings and take the first step toward a more efficient system.
