Manufacturing facilities spend around 40% of their total energy costs on compressed air alone, making an efficient compressed air system critical for maintaining a healthy bottom line. Unfortunately, not all systems operate in the most efficient manner possible, and we see it every day – compressors not appropriately sized, outdated technology, air leaks, pressure drops – the list can go on and on.
Increasing energy costs is a widespread concern. The U.S. Department of Energy has estimated that over 50% of industrial air compressors are not running efficiently, resulting in 3.2 billion dollars of energy waste annually. The good news is that manufacturers included in this study that dedicated resources to lowering energy costs were able to save upwards of 15% annually with a payback of fewer than two years.
So, how can you ensure an efficient compressed air system at your plant?
For more information on walk-through evaluations, system assessments or system audits, please visit https://www.compressedairchallenge.org.
Manufacturers using compressed air regardless of the industry – food and beverage, automotive, textile, power, electronics, plastics to name a few will often find that a compressed air audit will pay for itself. Depending on the results of the audit, manufacturers can expect to see improvements in energy efficiency and system reliability and lower operating costs.
As an example, during an audit, some manufacturers find that their plant air systems operate at a higher pressure than the actual demand of the plant due to pressure drops, air leaks or excessive bends in piping design. If a plant requires 100 psi, but due to air loss they must produce 120 psi, they are wasting 20 psi. Performing an audit of your system can help you identify sources of energy waste like this.
Before scheduling an air audit, we welcome you to run an AirCompare report to better understand how the type of compressor technology you are employing may be contributing to your energy costs. After receiving your results, you may elect to receive a more thorough cost analysis of your current compressed air solution.