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As facilities continue modernizing their operations, compressor control systems have become one of the most effective areas to improve reliability, energy efficiency, and day-to-day visibility. What began decades ago as simple protection logic has evolved into a plant-wide intelligence platform that helps operators run cleaner, safer, and more efficiently.
This blog highlights how compressor controls have evolved, why modernization matters, and what today’s systems can offer, while our latest Beyond Compression podcast episode takes a deeper dive into the full discussion.
Before the 1960s, compressor controls focused primarily on basic protections such as overspeed and surge. As manufacturing needs increased, relay-based systems introduced simple sequencing and monitoring throughout the 1960s and 1970s.
The most significant transformation occurred in the 1980s through the early 2000s with the introduction of microprocessors and PLC-based platforms. Operators gained clearer interfaces, improved feedback, and the ability to connect compressors into broader plant networks.
Today’s control systems build on that foundation with faster processors, improved diagnostics, and predictive capabilities that help operators address issues before they escalate, improving both stability and efficiency.
Upgrading compressor controls is often one of the most cost-effective ways to enhance compressed air performance. Modern panels provide improved reliability, expanded protection logic, and better visibility through intuitive touchscreens and advanced monitoring features. Seamless integration with plant networks enables more cohesive operation, while optimized control modes help lower energy usage and reduce venting.
If your current system relies on outdated HMI hardware, is restricted to base mode, or cannot communicate with plant systems, modernization may offer significant gains in uptime and efficiency.
FS-Elliott offers three Regulus control panels designed to support a wide range of operational needs:
All three Regulus panels include the following features designed to support long-term performance:
A range of standard and optional modes are available to further expand the capability of Regulus control panels, including:
Modernizing your control system is a straightforward process. Our pre-engineered retrofit kits include all the required hardware, cabling, and configured components, designed for efficient installation across the R1000, R2000, and R3000 platforms. Installations for the R1000 and R2000 are typically completed in under a week, while timelines for the R3000 vary depending on system complexity.
These retrofit packages ensure a controlled, low-disruption transition to advanced control functionality.
A recommended starting point is a no-cost controls health check. Our team will analyze your current control modes, energy consumption, and system performance to define the most appropriate modernization strategy for your facility.
This overview highlights the core advantages of modern compressor control systems, but the complete discussion offers deeper context, real-world examples, and expert analysis.
Listen to the full conversation in our latest episode of the Beyond Compression podcast:
For further information or to request a control system evaluation, please contact our team.
Contact us today to learn more about the benefits of employing an FS-Elliott compressor at your facility.
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