10 Ways to Reduce Compressed Air Energy Costs

Compressed air is an essential part of many industrial and manufacturing operations, but it can also be one of the more expensive utilities to run. Inefficient compressors, excessive pressure, air leaks and poor maintenance can all increase energy consumption and operating costs.

The good news is that there are several practical ways to improve the efficiency of a compressed air system and reduce energy costs.

1. Find and Repair Air Leaks

Air leaks are one of the most common sources of wasted energy in compressed air systems.

Even a small leak can waste significant amounts of compressed air over time, forcing your compressor to run for longer to maintain system pressure.

Regular leak detection surveys can identify leaks in pipework, fittings, hoses, valves and other components so they can be repaired before they become an expensive problem.

2. Reduce Unnecessary System Pressure

Running a compressor at a higher pressure than necessary can increase energy consumption.

Check the operating pressure requirements of your equipment and make sure the system is not producing more pressure than needed.

Reducing system pressure, where appropriate, can provide energy savings while still maintaining reliable operation.

3. Keep Compressors Properly Maintained

Regular servicing helps ensure your compressor continues to operate efficiently.

Blocked filters, dirty coolers, worn components and incorrect oil levels can all affect compressor performance and increase energy consumption.

Following the manufacturer’s recommended service schedule is an important part of keeping running costs under control.

4. Choose the Right Compressor

A compressor should be matched to the actual requirements of your business.

An undersized compressor may run continuously and struggle to maintain pressure, while an oversized compressor can result in unnecessary capital and energy costs.

Consider your required airflow, operating pressure, duty cycle and future requirements when selecting a compressor.

5. Consider Variable Speed Technology

If your compressed air demand changes throughout the working day, a variable speed compressor (VSD) may help reduce energy consumption.

Unlike a fixed speed compressor, a variable speed machine can adjust its output to match air demand, reducing unnecessary energy use during periods of lower consumption.

6. Maintain Your Air Filters

Blocked or dirty filters can create pressure drops within the compressed air system.

The compressor then has to work harder to maintain the required pressure.

Regularly inspect and replace filters as recommended to maintain good airflow and minimise unnecessary pressure losses.

7. Use an Efficient Air Dryer

Moisture needs to be removed from compressed air in many applications, but the drying equipment itself also consumes energy.

Make sure your dryer is correctly sized for your compressor and application and is properly maintained.

Modern energy-efficient dryers and zero-loss drains can help reduce unnecessary energy consumption.

8. Check Your Pipework

Poorly designed or undersized pipework can create unnecessary pressure drops.

A well designed compressed air distribution system should provide adequate airflow while minimising pressure losses.

Regularly inspect pipework, fittings and connections for leaks, corrosion or damage.

9. Avoid Using Compressed Air Where You Don’t Need It

Compressed air can be an expensive way of performing simple tasks.

For example, using compressed air for cleaning floors, machinery or work areas can consume large amounts of energy.

Where practical, consider alternatives such as brushes, vacuum systems or dedicated electric equipment.

10. Monitor Your Compressed Air System

You cannot manage what you don’t measure.

Monitoring compressor performance, pressure, airflow and energy consumption can help identify changes in system efficiency and highlight potential problems.

Regular monitoring can also help you understand your actual air demand and determine whether changes to your compressor or distribution system could reduce operating costs.

Small Changes Can Make a Big Difference

Reducing compressed air costs doesn’t always require a completely new system. Simple improvements such as repairing leaks, reducing unnecessary pressure and maintaining equipment properly can make a significant difference.

For businesses with larger or more complex systems, a professional compressed air survey can help identify opportunities for improved efficiency and energy savings.

How Air System Controls Can Help

Air System Controls provides a range of compressed air services, including air leak detection, compressor servicing, repairs, system design and compressed air pipework installation.

If you’re concerned about the energy costs of your compressed air system, our team can help identify potential sources of wasted energy and recommend practical solutions.

Contact Air System Controls to discuss your compressed air requirements and find out how you could improve the efficiency of your system.