How to improve your compressed air audit result in 7 steps?
11 May, 2026
An energy audit helps to analyze the efficiency of compressed air systems. Find out how you can increase your efficiency and save money in the process.
Metode za uštedu energije utrošene u vazdušnim kompresorima - koliko mogu uštedeti?
Ekološki kompresori štede novac. Korišćenjem znatno manje količine energije, smanjuju troškove proizvodnje komprimovanog vazduha i pošto troškovi energije čine značajnu većinu ukupnih troškova posedovanja kompresora, onda ova smanjenja troškova mogu biti značajna na vašem računu za energiju.
Ali postoji li način da se tačno izračuna koliko preduzeće može uštedeti ako postane „zeleno"? Ovo je posebno važno pitanje za manja preduzeća, koja mogu biti zabrinuta zbog veće početne nabavne cene energetski efikasnog kompresora. Njima se može učiniti da bi „sigurna“ opcija bila da nastave da koriste svoj stari kompresor iako stvara ogroman račun za struju.
Međutim, nema ničeg bezbednog u zadržavanju stare tehnologije u vreme kada oni koji odluče da pređu na „zelenu" tehnologiju uživaju značajnu konkurentsku prednost. U stvari, neprelaženje na ekološki prihvatljivu tehnologiju je mnogo rizičnije jer dovodi i do neizvesnosti u proizvodnim procesima.
„Zeleni" vazdušni kompresori pružaju stabilnost. Oni ne samo da garantuju da će kompanija sniziti troškove proizvodnje komprimovanog vazduha, zbog čega su zaštićeniji od velikih fluktuacija cena energije, nego nude i veću pouzdanost, duže intervale održavanja i obezbeđuju usklađenost sa trenutnim i nastupajućim standardima emisije.
Energy typically accounts for over 70% of a compressor's total cost of ownership. Quantifying the savings potential before committing to any upgrade allows engineers to prioritise measures and build a credible ROI case.
Savings calculation inputs engineers need
To estimate annual energy cost, you need four measured or estimated values:
- Average power draw (kW): use metered values from the controller or a power analyser, not the motor nameplate rating
- Operating hours (h/year): from controller logs or production schedules
- Electricity price (EUR/kWh): from utility bills, using the blended tariff
- Flow (m³/h): from a flow meter or controller estimate, needed for specific energy calculations
Annual energy cost (EUR/year) = Average power (kW) × Operating hours (h/year) × Electricity price (EUR/kWh)
Annual savings (EUR/year) = (Baseline power − Improved power) (kW) × Operating hours (h/year) × Electricity price (EUR/kWh)
If specific energy is available: Cost (EUR/year) = Specific energy (kWh/m³) × Annual volume (m³/year) × Electricity price (EUR/kWh)
Practical example
Assumptions: 75 kW average power, 4,000 h/year, 0.18 EUR/kWh.
Baseline cost: 75 × 4,000 × 0.18 = EUR 54,000/year
Savings at 10% power reduction: EUR 5,400/year
Sensitivity: at 0.12 EUR/kWh the same reduction yields EUR 3,600/year; at 0.25 EUR/kWh it yields EUR 7,500/year. Savings scale linearly with electricity price.
| Parameter | Symbol | Example value | Notes |
|---|---|---|---|
| Average power | kW | 75 kW | Measured, not nameplate |
| Operating hours | h/year | 4,000 | From controller logs |
| Electricity price | EUR/kWh | 0.18 | Blended tariff from bill |
| Baseline annual cost | EUR/year | 54,000 | kW × h × EUR/kWh |
| Improvement | % | 10% | Target reduction |
| Annual savings | EUR/year | 5,400 | Baseline cost × improvement % |
| Simple payback | years | 3.7 | Investment / savings |
Simple payback (years) = Investment (EUR) / Annual savings (EUR/year)
Using the example above: a EUR 20,000 investment at EUR 5,400/year savings gives a payback of approximately 3.7 years.
Savings estimates should always be expressed as a range. Operating hours and demand variability typically introduce an uncertainty of ±10–20%. A conservative estimate using the lower bound of the electricity price range is advisable for internal approval submissions.
Dobijanje pomoći za utvrđivanje konkretnih ušteda
U većini slučajeva, direktne i indirektne uštede, kao i koristi od prelaska na „zeleni" kompresor biće značajne, a posebno niži troškovi proizvodnje komprimovanog vazduha kao rezultat smanjenja troškova energije.
Konkretna cifra zavisi od faktora kao što su potrebe kompanije za komprimovanim vazduhom ili tip kompresora koji izaberu. Posedujući te informacije, stručnjaci Atlas Copco mogu pomoći pri izračunavanju uštede koju preduzeće može da ostvari kupovinom „zelenog" vazdušnog kompresora.
Metode za uštedu energije utrošene u vazdušnim kompresorima
Savings come from both equipment selection and system optimisation. The main categories of action are pressure management, pressure-drop and leak control, master control and automation, and heat or energy recovery. For reference, each 1 bar reduction in system pressure can reduce power consumption by approximately 8%.
The following plant-level measures focus on reducing wasted pressure and runtime while maintaining required point-of-use pressure.
Učiniti da sistemi komprimovanog vazduha budu još efikasniji
Optimising an existing compressed air network typically offers more than one route to reducing energy consumption. The measures below address the most common sources of waste: excess pressure, distribution losses, inefficient control, and unrecovered heat.
Every 1 bar increase in system pressure requires approximately 8% more power, which means raising the setpoint to compensate for pressure drop is an expensive workaround. Pressure setpoint optimisation and pressure-drop control are therefore among the highest-impact actions in any compressed air system.
The correct approach is to identify and eliminate the source of the drop. Measure pressure at three points: compressor outlet, main header, and the most distant point of use. The total pressure loss across the distribution network should not exceed 0.1 bar.
Worked example: At 75 kW baseline power and 7 bar, a 0.5 bar unnecessary pressure increase adds approximately 3 kW. At 4,000 h/year and 0.18 EUR/kWh, that equals EUR 2,160/year in avoidable cost.
Increasing the pressure setpoint should always be a last resort, used only after leaks, undersized pipework, clogged filters, and ageing equipment have been investigated and addressed.
Leak detection and quantification
Leaks are one of the most common and costly sources of compressed air waste. A 2 mm leak at 8 bar can cost thousands of euros annually. To quantify leakage: establish a no-production baseline by running the compressor outside production hours and recording average flow (m³/h). This flow represents system leakage. Convert to annual cost using:
Leak cost (EUR/year) = Leak flow (l/s) × 3,600 × Operating hours (h/year) × Specific energy (kWh/m³) × Electricity price (EUR/kWh). Use ultrasonic detection equipment to locate leaks under load. Prioritise by leak size and accessibility.
Controls and master controller strategy
A master control system coordinates multiple compressors to match output to demand, minimising unloaded runtime and keeping header pressure within a narrow band. Required sensor inputs: pressure at the header and at the most distant point of use, flow (m³/h), and compressor power (kW).
Sequencing objective: run the minimum number of machines at full load (base load) and use one trim machine to handle demand variation. Avoid running multiple fixed-speed machines unloaded simultaneously. A master controller can also automatically reduce working pressure during low-demand periods such as nights and weekends, delivering savings without any manual intervention.
Energy recovery opportunities
Prelazak na „zeleno" ne odnosi se samo na kupovinu novog kompresora. Optimizacija njihove postojeće mreže komprimovanog vazduha obično nudi preduzećima više od jedne opcije za smanjenje ugljeničnog otiska i troškova komprimovanog vazduha. Sistem komprimovanog vazduha zahteva pažnju i negu. Zanemarivanje će uvek dovesti do neefikasnosti koja može biti prilično skupa.
Zato sistem komprimovanog vazduha treba pažljivo pratiti i kontrolisati. Jednostavan primer je radni pritisak vazduha. Veći pritisak znači povećanu potrošnju energije, što znači veće troškove proizvodnje. U proseku, 1 dodatni bar pritiska rezultira u proseku povećanjem potrebne snage od 8%. To se brzo nadodaje.
Mnoge kompanije prave grešku jednostavno povećavajući svoj radni vazdušni pritisak kada dođe do pada pritiska u njihovom vazdušnom sistemu. Iako se to čini kao jednostavno rešenje, ono je i skupo i brzo dovodi do povećanja cene komprimovanog vazduha.
Na primer, curenje od dva milimetra pri pritisku od 8 bara kompaniju može koštati hiljade dolara godišnje. Zato je ključno istraživanje uzroka pada pritiska, koji može biti bilo šta, od curenja do cevovoda nedovoljnih dimenzija, stare opreme ili začepljenog filtera.
To znači da operateri uvek treba da budu svesni koliki im je pritisak zapravo potreban i gde njihov sistem može izgubiti pritisak. Kao pravilo, mreža komprimovanog vazduha treba da bude projektovana tako da gubitak pritiska između kompresora i najudaljenije opreme koja troši vazduh ne bude veći od 0,1 bar.
Sve ostalo će se brzo odraziti na račun za struju kompanije. Dobar način upravljanja sistemom komprimovanog vazduha je primena najsavremenijeg glavnog kontrolnog sistema koji prati njegovu efikasnost, dostupnost i pouzdanost. Ne samo da detektuje probleme, već i automatski smanjuje radni pritisak, odnosno smanjuje troškove kada je potražnja za vazduhom mala, na primer noću ili vikendom.
Još jedan dobar način za smanjenje troškova je dodavanje sistema za povratak energije u mrežu komprimovanog vazduha. Više od 90 procenata energije koju kompresor koristi može se povratiti u obliku toplote, koja se može iskoristiti na drugim mestima. Kao rezultat toga, investicija u takav sistem se često isplati za manje od tri godine.
Najvažnija stvar koju treba zapamtiti je da se skoro svaka mreža komprimovanog vazduha može poboljšati, posebno one koje ne koriste najsavremeniju opremu i najsavremenije kontrolere. A za još veću uštedu, proverite kod stručnjaka Atlas Copco kako biste saznali kako vaša kompanija može imati koristi od prelaska na „zeleno".
Decision criteria for energy recovery investment
- Year-round heat demand on site (space heating or process water)
- Ducting distance between compressor and heat application point
- Required delivery temperature (degrees C) vs compressor outlet temperature
- Maintenance access and integration with existing heat systems
When conditions are favourable, payback on an energy recovery system may be often under three years.
Pogledajte uticaj vaše uštede energije na životnu sredinu
Energy savings translate directly into CO₂ emissions reductions. Use the following method to estimate the carbon impact of any efficiency improvement:
CO₂ saved (kg/year) = Energy savings (kWh/year) × Grid emission factor (kgCO₂/kWh)
Use the emission factor for your facility's location and grid mix. For India, refer to the current Central Electricity Authority (CEA) emission factor.
Worked example: 30,000 kWh/year in energy savings at an emission factor of 0.70 kgCO₂/kWh yields 21,000 kgCO₂/year (21 tCO₂/year).
| Annual energy saved (kWh) | Emission factor (kgCO₂/kWh) | Annual CO₂ saved (tCO₂) |
|---|---|---|
| 10,000 | 0.70 | 7.0 |
| 30,000 | 0.70 | 21.0 |
| 54,000 | 0.70 | 37.8 |
Use CO₂ savings alongside EUR/year figures to prioritise projects and support internal sustainability reporting.
Step 1: Select your currency and unit of measurement
Step 2: Fill in your annual running hours, system power, and electrical cost per hour
Step 3: Choose the percentage of energy saving
1 bar air pressure band reduction: 7%
Changing from fixed speed to VSD: 35%
Changing from fixed speed to VSD+: 50%
Installing an energy recovery system: 94%
Step 4: Select the numbers of years to visualize saving over time
Have a look at the estimation of your reduction in electricity costs and your CO2 reduction. To make it more tangible, we visualized the reduction in CO2 in more common comparisons such as CO2 emissions from charged smartphones and a households' yearly electricity use.
Could a new compressor cut your costs?
An aging or oversized compressor can quietly drain your budget. Share your compressor type, pressure setpoints, operating hours, and flow profile to get a site-specific assessment with quantified EUR/year savings and CO₂ impact.
How do I calculate energy savings and payback for a compressor upgrade?
Multiply average power (kW) by operating hours (h/year) and electricity price (EUR/kWh) to get annual energy cost. Savings equal the power reduction (kW) multiplied by the same hours and price.
Example: a 10% reduction on a 75 kW system at 4,000 h/year and 0.18 EUR/kWh saves EUR 5,400/year. Divide the investment by annual savings to get payback: EUR 20,000 / EUR 5,400 = 3.7 years. Add a ±10–20% margin to account for demand variability.
Does a VSD compressor always save more energy than a fixed-speed machine?
Not always. A VSD saves most where demand fluctuates regularly, as it avoids the unloaded running losses of a fixed-speed machine. At constant full load, a fixed-speed compressor is typically more efficient.
As a general rule, if demand varies by more than approximately 20–25% of rated capacity, a VSD delivers lower specific energy (kWh/m³).
How much does raising system pressure by 1 bar increase energy costs?
Approximately 8% more power per bar added. Before raising the setpoint, check for leaks, clogged filters, undersized pipework, and ageing equipment. These are the most common causes of pressure drop. Distribution losses should not exceed 0.1 bar. Raising the setpoint should always be a last resort.
What causes pressure drop in a compressed air system and how do I find it?
The most common causes are leaks, undersized pipework, clogged filters, and ageing equipment. Measure pressure at the compressor outlet, main header, and most distant point of use. A difference greater than 0.1 bar across the distribution network signals a problem. Use ultrasonic detection to locate leaks under load, and check filter differential pressure indicators regularly.
How does a master controller cut energy use without risking production uptime?
It monitors pressure, flow, and power in real time and automatically reduces the pressure setpoint and sequences compressors during low-demand periods such as nights and weekends. At least one machine stays available to respond to demand spikes. The result is lower energy use with no manual intervention and no uptime risk. Track unloaded runtime (%), header pressure (bar), and specific energy (kWh/m³) to measure the impact.
How does heat recovery work and what payback can I expect?
More than 90% of a compressor's energy input can be recovered as heat for space heating or process water. Multiply compressor input power (kW) by the recoverable fraction to estimate available heat. When there is year-round heat demand on site and ducting distances are short, payback is often under three years. Verify payback claim against Atlas Copco reference data.
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