10 tips to boost drilling efficiency and cut fuel costs
September 5, 2025
Let’s face it—fuel is one of the biggest costs in drilling operations. And with prices fluctuating, every liter and gallon saved is money in the bank.
The good news? You don’t need to overhaul your entire setup to see a difference. Small changes in how you choose, use, and maintain your portable air compressor can lead to big savings.
Here are 10 smart, practical ways to boost fuel efficiency on your drilling site.
Operators in PPE gear managing a drilling rig during a field test of Atlas Copco's DrillAir portable air compressors for fuel efficiency
1. Choose the right compressor size
Bigger isn’t always better. Running a compressor that’s too powerful for the job wastes fuel—fast. Match your mobile air compressor to your actual pressure and flow needs. For example, our X-Air+ 750-25 portable air compressor is well-suited for medium-depth drilling.
In our recent field test, the X-Air+ 750-25 portable air compressor drilled 250 meters (820 feet) in 6.5 hours. It used only 290 liters (76.6 gallons) of fuel. This shows a great balance of power and efficiency.
2. Let smart controls do the thinking
Today’s portable air compressors feature smart control systems that modify engine speed according to demand. The DrillAir range comes with smart controllers (Xc4004) and AirXpert systems. These automatically adjust engine speed and balance flow/pressure for optimum output, so you burn less fuel when you’re not at full load. It’s like cruise control for your compressor—smooth, efficient, and stress-free.
3. Dial in the right pressure
4. Keep it clean
Dirty filters and clogged coolers make your compressor work harder (and burn more fuel). A quick check and clean can go a long way in keeping things efficient.
5. Minimize load/unload cycles
Frequent load/unload cycles are fuel killers. Choose compressors with smart load management or variable speed drives to keep things running smoothly and efficiently. AirXpert and the controller’s load management help smooth out these cycles, avoiding unnecessary fuel consumption.
6. Avoid unnecessary idling
Leaving your air compressor idling during breaks? That’s fuel literally going up in smoke. Train your team to shut down during long pauses—or better yet, use models with an automatic stop/start ECO-mode to handle it for you.
7. Drill smarter, not harder
Fuel efficiency isn’t just about the compressor. Using the right drill bits, feed pressure, and rotation speed can reduce the time (and energy) it takes to get the job done. Features like Dynamic Flow Boost on DrillAir units can speed up flushing and refilling steps, shaving time off every rod change.
8. Upgrade to fuel-efficient models
Not all compressors are created equal. In our recent field test, the X-Air+ 1200-40 drilled 400 meters (1312 feet) in 7.5 hours. It used 529 liters (140 gallons) of fuel. This was better than a similar 35 bar unit, which used 587 liters (155 gallons) for the same depth. That’s the kind of efficiency that adds up fast.
9. Monitor fuel consumption
If you’re not measuring fuel use, you’re guessing. Use telematics or even a simple logbook to track consumption and spot trends. You can’t improve what you don’t monitor. The Xc4004 controller stores and displays detailed operating data that makes this easy.
10. Train like it matters (because it does)
No matter how good the drilling equipment is, inefficient use won't conserve fuel. Regular training helps your team get the most out of your machines—and your fuel budget.
Want to see fuel efficiency in action?
We recently tested our DrillAir portable air compressors: X-Air+ 750-25, Y35, and X-Air+ 1200-40. We did this in a real drilling situation and recorded it all in a time-lapse video. Curious which model came out on top?
