10 tips to save compressed air (free eBook)
Compressed air is one of the most expensive utilities in your manufacturing plant, often accounting for a significant share of total energy consumption. Inefficiencies such as leaks, pressure losses, inappropriate use and poorly controlled compressors can silently drive up operating costs and CO₂ emissions. Yet many facilities lack clear insight into where and how compressed air is actually being used, making it difficult to identify and prioritize savings opportunities.
With the right measurement and monitoring, however, compressed air systems can be optimized effectively. By understanding flow, pressure, and consumption patterns, you can uncover hidden losses and take targeted actions to improve efficiency and reliability. In this eBook, we present ten practical, high-impact tips to reduce compressed air consumption and help you achieve immediate and sustainable energy savings.
1. Shut off sections and machines that you do not use
A simple manual or motorized valve can save you thousands of euros/dollars. Make sure that air is not lost through leaks or machines standing in idle mode. Flow meters help to determine to which sections air is flowing.
2. Breathe cool, fresh and clean air
A compressor converts 90% of its power into heat. The compressor room heats up, while a compressor uses less energy to compress cold air. 3°C cooler air, already results in 1% energy savings.
3. Invest in an efficient control system
Have insight in your compressed air usage profile, so you can optimize your compressor control system. Ask an air audit specialist to perform an air audit, and make an improvement plan based upon the results.
4. Think about the required air quality
Clean compressed air is important for the life span of your compressed air installation. Choose the right quality carefully for specific processes whenever possible, as higher air quality results in higher energy costs.
5. Reduce offload hours
Electricity consumption of a compressor in offload stage costs 10-35% of the consumption during load hours. At >80% use of the capacity, the offload-loadcontrol is considered efficient. Choose the right control system.
6. Manage your leakage
In general, there is 20-40% of leakage in a compressed air installation. VPVision can be used as a global leakage management system and helps you to rank the leaks on savings potential. Invest in an ultrasound leak detector to find the leaks.
7. Balance your system
Is your compressor oversized? In some applications the compressor is bigger than necessary, for instance after changes in the production process. The payback time of the investment in a smaller compressor is often short.
8. Reduce the pressure
Every bar pressure reduction gives an instant win of 7% on your energy consumption. Invest in pressure regulators per production area, use buffer vessels and reduce pressure swings in your network.
9. Think of alternative uses
Compressed air is 8 times more expensive than electric power. However, compressed air is often used, simply because it is present. The VPFlowScope offers insight in the usage and helps you to select the right solution.
10. Choose the right pipe size and material
A proper pipe system is crucial to limit your pressure drop. Iron pipes tend to rust. Too small piping creates pressure loss. Use angular feed-ins on the main header to reduce pressure loss.
VPVision: the solution for energy monitoring
The advantages of compressed air monitoring are clear. But which system do you use for this? One very complete solution for energy monitoring is VPVision. VPVision makes energy savings simple, fast and cost-effective. The VPVision monitoring system collects information via analogue sensors and Modbus/TCP sensors, which are installed strategically in your factory. The data of your sensors are collected and stored, and can be viewed in real time on any PC via Ethernet. The VPVision dashboard can be arranged to fit your needs. Via alarms and reports critical information is send to your email inbox.
The possibilities of compressed air monitoring for your company
Are you ready to optimise your production process and save money? Our experts are happy to talk you through the possibilities and guide you every step of the way. Contact us today!
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