Small Adjustments = Big Savings

We know compressed air is costly. You need it for production and the cost of electricity is increasing. So the question begs, "What can I do?" Manufacturers are looking for ways to do more with less. I will touch on a few points aimed to keep your costs down and keeping your system efficient.

Suggestion One - Assess your system

The best thing you can do is track your compressed air. It is recommended that you conduct an air audit every few years. If you want to go above and beyond, installing a system to monitor and record your systems pressure, flow, and kWh would put you in the front of the race.

In addition to monitoring and tracking your compressor, you must review the data. Having these numbers and graphs are great but if you should use the information to better your system. If you are not comfortable to review the data and their meanings on your own, then please invite a professional to teach you and clarify. Be sure to know who you are inviting; you would want a third party impartial conductor. There are some great audit workers that care about the air. Look for a reputable, trustworthy consultant with a proven track record. On the other hand, if you have a good relationship with your service provider and they offer auditing services, by all means, do what you think is the right way to approach. Just know there are options.

Suggestion Two - Maintain your system

You have invested a lot in your system, it's imperative that you keep your investment protected. Regular maintenance by a knowledgable, competent technician will make all the difference. Remember, the air being used comes in contact with your product, you want to ensure clean, dry, air to maintain consistency. Quality assurance will appreciate it too. Proper, regular maintenance will reduce downtime, prepare a budget and schedule for any potential problems that may have been identified.

Suggestion Three - Lower the pressure

Chances are you aren't the only person who touches the compressor. It's not uncommon for people to turn the pressure up if they aren't getting the air they need. Find your sweet spot. Lowering your pressure will save you money! Here's another way of thinking about leaks; When you climb a mountain, the last 2,000 feet is much tougher than the first.

In an article, on buildings.com, a rule of thumb, is that for every 2 psi you can reduce, you will save 1% of energy used by a compressor operating in the 100 psi range.

I once did a compressed air audit at a factory that resulted in a $1.6 million energy savings per year. When I presented it, the plant manager looked at me and said, “Even if you're half wrong, this is still a great savings and the costs will be returned in less than a year.” Eric Woodroof PH.D., CEM, CRM

Suggestion Four - Fix the leaks

Every plant has leaks, it's just the way it is. Piping changes due to temperature, things break, cheap fittings, inoperative tools, the list goes on and on.

Ron Marshall posted a great article here https://www.plantservices.com/articles/2018/ca-money-in-your-pocket-fix-your-compressed-air-system-leaks/

By no means, fixing leaks and reducing pressure will be the game changer for your compressed air system. It takes continuous work. There are always opportunities to improve the system. Small changes can make a difference in the long run. Having a handle on your compressed system requires frequent assessments.

Working with the right compressor service company will make a difference. In anything I do, I want to be taught not told. If you are confident with the information provided to you, you can make an educated decision in moving forward.

I could go on for days about compressed air, but each system is different. I would love to be invited into your plant for a gap analysis. We will talk about your situation and concerns, walk through the plant, and I will provide you with a short summary report including recommendations, all complimentary of course.

Suggestion Five - Make a move

Please call or email me, (905) 681-6687 or [email protected]

I look forward to meeting you and am eager to help your system become more efficient!

Thank you for reading.

Disclaimer: The views and opinions expressed in this article are those of the authors and do not necessarily reflect the official policy or position of any agency. Examples of analyses performed within this article are only examples. They should not be utilized in real-world analytic products as they are based only on very limited and dated open source information.