menu
Five Ways to Save Money on Air Compressor
Investing in an air compressor for your manufacturing plant is not a decision to take lightly, for compressed air is the "fourth utility" and the most expensive by far.

Investing in an air compressor for your manufacturing plant is not a decision to take lightly, for compressed air is the "fourth utility" and the most expensive by far. But there are methods to cut down the cost of compressed air. One simple, yet effective technique is to increase the efficiency of your compressed air system. You will be avoiding hefty added expenses, but you'll also be producing high-quality products, meeting environmental standards, and increasing your raw material availability.

One of the most important factors in a compressed air system is the compressor. The compressor is an integral part of the system, and is often the most costly piece on it. The best way to reduce the cost of your air compressor is to make sure the machine you purchase has a high-efficiency compressor. This will increase the amount of output you get from one unit. The higher the compressor's efficiency level, the less it will cost you to purchase and operate.

PowerHouse Oil Free Air Compressor 1440 r/min TB550W-25L

Here are the top five ways to cut down compressed air costs:

Five Ways to Save Money on Air Compressor

1. Locate and repair leaks.

Compressed air leaks may begin tiny, but they can quickly grow into a major issue. Leaks in your air compressor machine can increase the machine’s energy expenditures by 30% or more. According to a study, up to 35 percent of compressed air is wasted on average.

Find and repair leaks in your compressed air system to reduce energy expenditures. You might be able to find some by listening for the hiss near the leak site. Air loss is frequently caused via hoses, fittings, and connectors. However, to discover smaller leaks, you will most likely need to hire an expert to perform a compressed air system audit. During the audit, the technician will utilise an ultrasonic acoustic detector to locate too small leaks for human detection. Leaks can be repaired by tightening connections, replacing faulty fittings, or patching or replacing damaged piping portions.

Because leaks can occur at any time, this is not a one-time remedy. Leaks in your system should be checked regularly.

2. Examine the plant pressure.

Checking the overall plant pressure is your second opportunity for significant energy savings in your air compressor. Many factories run at higher pressures than are required to run tools and equipment. Operating at higher pressures than necessary for effective equipment functioning provides no benefit. Reducing plant pressure could save you thousands of rupees on your annual energy cost.

On average, a two PSI reduction in overall plant pressure saves 1% in compressed air system energy expenses. Furthermore, many plants are operating at pressures that are 15 to 20 PSI higher than what they require. Lowering plant pressure by just 10 PSI can save up to 5% on compressed air energy expenses.

Why are industrial plants running at greater than necessary PSIs? One of the major culprits is excessive pressure decrease. This could be due to leaks in the compressed air distribution system (as mentioned above), filled inline filters, or other system blockages. To compensate for pressure loss at the end of the lines, manufacturers may increase the PSI for the entire system, ensuring that tools at the end of distribution runs function properly. However, addressing the source of the pressure drop and lowering the PSI is nearly always more cost-effective in the long run.

 

Orbit 9 L 0.5 HP Oil Free Compressor - OG 9L

3. Reduce wasteful air usage.

Compressed air waste is caused by more than only leaks in many plants. Compressed air waste can add up to your annual energy expenses. Some of the most common offenders are:

      Clean-up/blow-off

      Process cooling or drying

      Sparging

      Individual cooling

In each of these circumstances, compressed air is an expensive solution to the problem at hand. It may be easier (or enjoyable) to blow sawdust off a workstation than to take up a brush or broom, but it is not the most efficient or effective approach to clean. Furthermore, compressed air is not required for drying, cooling, or sparging applications. Standard fans or blowers better serve these procedures. Before using an air compressor for an application, consider whether pressured air is genuinely required and whether there are better (and less expensive) alternatives.

Another source of compressed air waste is idle machinery. Even when the equipment is not working, small breaches in valves or couplers providing air to it can cause air loss. Unused equipment should be disconnected from your compressed air system, and air valves for equipment that has been idle for an extended period should be turned off.

Employees may need to be retrained in order to reduce compressed air waste. Small adjustments in behaviours and processes can have a huge impact on overall air consumption. 

4. Regular maintenance

An industrial air compressor requires regular maintenance. Preventative maintenance will increase your machine’s energy efficiency and save running expenses.

Compressed air filters that are clogged or laden, in particular, can be an energy drain in your compressed air system. It requires more power to move air through filters as they become clogged with particulates. The pressure drop over the filter demonstrates this. When you fail to change your filters on a regular basis, your compressed air system needs to work harder.

Change compressed air inline filters at least once a year or after 8,000 hours of operation. If the intake air is exceptionally unclean or your compressor has a lot of oil carryover, they may need to be changed more frequently. Check and replace the air intake filter on a regular basis as well.

In addition to performing the regular compressor PM operations, ensure that the area around the compressor is clean and permits adequate airflow to prevent compressor overheating. Keeping the area around the compressor clean reduces the amount of particulate that winds up in your filters, extending the life of the filters. Inspect your distribution system as well to ensure that there are no obstructions caused by corrosion or other pollutants in the system. A clean, well-maintained compressed air system will perform optimally.

 

PowerHouse 1.5 HP Air Compressor 30 Ltr PH1530

5. Consider a variable speed drive (VSD) air compressor.

If your compressed air usage fluctuates throughout the shift, day, or season, a variable speed drive (VSD) air compressor machine may be beneficial. A VSD compressor ramps the motor's speed up or down in response to real-time demand. For example, when demand is low, the motor runs at a slower speed, saving energy. In contrast, a fixed-speed air compressor always operates at full capacity, even when air demand is minimal. A VSD compressor can reduce energy consumption by up to 70% in rare cases!

A VSD compressor maximizes savings for establishments that employ variable compressed air. Switching to a VSD compressor may not be as beneficial for fully robotic facilities that use compressed air at the similar rate 24/7/365. However, for buildings with intermittent air consumption throughout the day or large fluctuations in demand from season to season, a VSD can significantly reduce energy expenses.

Conclusion

To understand the importance of the air compressor and how to choose a model that is right for you, you will first need to understand the purpose of the machine. To find good deals on an air compressor machine, visit www.industrybuying.com.

The best way to reduce the air compressor price is to make sure the machine you purchase has a high-efficiency compressor. At www.industrybuying.com, you'll come across cost-effective products with bulk discounts and additional discounts running on the website. Our products are made using high-quality raw materials and cutting-edge mechanism.