Compressed Air Optimisation: A Complete Guide

Read on 11 Proven Tips to optimise your Compressed Air System

Optimising compressed air systems is crucial for reducing energy costs and boosting efficiency. This guide covers pressure settings, air treatment, and 11 actionable tips to save energy, reduce downtime, and enhance productivity in industrial operations.

Introduction

Compressed air can be one of the most expensive utilities for an industrial operation, often accounting for a significant portion of total energy costs. Therefore, focusing on installing a compressor system that reduces energy consumption is essential and can generate substantial long-term savings. Investing in technology such as variable speed compressors can significantly reduce energy costs, improve productivity, and enhance competitiveness in the market. In this blog, we cover the essentials of managing your compressed air system, including budgeting, efficient use of energy, and the benefits of an optimised compressed air setup. This guide will help you understand how to get the most from your compressed air system and realise significant savings.

Table of Content

Why Compressed Air Optimisation is Important
Correct Pressure Matters
Compressed Air Consumption and Efficiency
Dry Compressed Air is Economical Compressed Air
11 Ways to Optimise Your Compressed Air System

Why Compressed Air Optimisation is Important

Compressed air systems are not just a means of powering tools—they represent a large portion of your energy consumption and operational costs. It's often called the "fourth utility" after electricity, gas, and water. Ensuring an efficient compressed air system can:

Save energy consumption
Reduce electricity costs
Decrease maintenance costs
Reduce equipment downtime
Increase productivity
Improve product quality

Correct Pressure Matters

The pressure you are operating with can play a significant role in the performance and efficiency of your compressed air system. Most industrial air tools are designed to work at an operating pressure of 600 kPa. The compressor’s pressure should be slightly higher to compensate for pressure losses along the way to the tool.

Lower pressure leads to reduced tool performance, slowing down production. For instance, if the pressure supplied to a drill falls from 600 to 500 kPa, the output can be reduced by up to 25%. However, too much pressure also has its drawbacks. An increase from 600 to 900 kPa can make a tool 50% stronger, but it also results in a 50% overload, shortening the life of the tool and increasing maintenance costs.

Additionally, increased operating pressure leads to higher air consumption, which increases energy usage and cost.

Compressed Air Consumption and Efficiency

Compressed air consumption changes with variations in operational pressure:

Operational Pressure (kPa)	Correction Factor
500	0.8
600	1.0
700	1.2
800	1.4
900	1.6
1000	1.8

For example, a grinding machine that consumes 700 l/min at 600 kPa will consume 1,120 l/min at 900 kPa. This highlights the importance of optimising pressure to save energy and costs.

Compressed air pressure is fundamental for the efficiency of the whole equipment

Dry Compressed Air is Economical Compressed Air

Moisture in compressed air can be damaging to your system. Without a compressed air dryer, moisture in the air leads to:

Corrosion in pipes and machinery
Increased wear on pneumatic tools
Additional maintenance for water separators and filters

Using a compressed air dryer eliminates these issues, leading to cost savings and prolonged equipment life.

11 Ways to Optimise Your Compressed Air System

Favourable Environment: Place your compressor equipment in a clean and well-ventilated space, with ample airflow and minimal dust or humidity. Proper ventilation and spacing between units extend the lifespan of compressors and improve efficiency.
Right Equipment Size & Technology: Choosing the right compressor—whether piston, screw, or centrifugal—based on required flow and pressure is essential. Oversized or undersized equipment can lead to energy wastage or reduced output.
Install Properly Sized Receiver Tanks: A central receiver tank after the compressor helps regulate load/unload cycles, reducing energy wastage. Local receiver tanks at high consumption areas can help avoid sudden pressure drops.
System Monitoring: Implementing monitoring, such as Icons and data collection can provide real-time insight into the compressor's performance, enabling proactive maintenance. Automated systems enhance efficiency by gathering and analysing data, which leads to optimised performance.
Improve Air Treatment Efficiency: Regular maintenance of air dryers and filters is key to efficient air treatment. Replace filters as needed to prevent energy loss from pressure drop or contamination.
Replace or Upgrade Equipment: Upgrading to a modern compressor with advanced features can reduce energy costs. Variable speed compressors, for example, save large amount in energy compared to fixed-speed compressors.
Advanced Central Control: Use central controllers to manage multiple compressor and dryer units efficiently, analyse performance data, and reduce excess air production.
Upgrade Piping: High-quality piping, such as AIRnet ensures efficient delivery of compressed air. Materials like aluminium and stainless steel prevent leaks and corrosion. Ensure air velocity remains below 6m/s to avoid issues like turbulence and backpressure.
Repair Leaks: Compressed air leaks account for up to 25% of energy loss in an unoptimised system. Identifying and repairing leaks can significantly reduce operational costs.
Environmentally Responsible Refrigerant: Opt for air dryers using eco-friendly refrigerants, which have minimal environmental impact.
Equipment Location and Heat Recovery: A centrally located compressor system is preferable to installing separate compressors at each work unit. It simplifies optimisation, reduces maintenance costs, and allows more efficient heat recovery.

Conclusion

Optimising your compressed air system is an ongoing process that involves careful monitoring, proper maintenance, and strategic upgrades. By following these best practices, you can reduce your energy consumption, increase your system's efficiency, and improve productivity while lowering costs. Remember, a well-maintained compressed air system is an economical one—both in energy consumption and reliability.

For personalised guidance on optimising your compressed air system, contact our experts today.

Got questions?

Have questions about choosing the right compressor for your specific needs? Our experts are here to help you make informed decisions that will improve your business processes and enhance your operational efficiency.

With decades of experience in compressed air, we offer a comprehensive range of screw compressors, piston compressors, oil-free compressors, and air treatment solutions. We also provide a wide range of service options to meet all your compressed air needs. Trust our expertise to deliver reliable, high-quality solutions at the forefront of innovation. With various connectivity options, we have a solution to meet your needs. Contact us today for personalised assistance and answers to all your questions!