Compressed Air Management
Improving Compressed Air System Performance
The truth is, after projects that reduce scrap, a compressed air system improvement project stands to be one of the largest and quickest payback projects your company can undertake. That's because compressed air is the most expensive form of energy in a manufacturing facility.
System inefficiencies can be driving your operating costs up and overtaxing costly air compressors and related capital equipment. Talk to a compressor manufacturer and they’ll say it’s time to buy a new compressor. Naturally, the bigger the better. But that might not be necessary.
Improve efficiency and performance while minimizing compressed air system project costs and you’ll see a quick and significant return.
Compressed air may be costing you more than you realize.
System inefficiencies directly impact your bottom line:
- Air waste results in higher than necessary costs.
- Fluctuating system pressures negatively impact air tool and air-operated equipment performance, adversely affecting production.
- Unnecessary cycling and increased run time decrease service life and increase maintenance.
The common misconception is that more PSI is the answer to everything. But PSI isn’t the issue. It’s CFM that gets the work done. So, you want your system CFM output to be as efficient as possible, which brings down PSI as well.
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On average, compressed air systems cost an organization approximately $1,000 per horsepower provided annually.
A ½ HP electric motor costs approximately $240/year to operate, while the compressed air motor equivalent costs more than $2,300.
Intimidated by the Scope of a Compressed Air Project?
If you don’t have the internal resources to take on a large project, we have you covered. Our fact-based, systematic approach and turnkey project management capability can help you get through your compressed air project stress-free. Our proven process includes these critical steps:
- Audit your compressed air systems on both the supply and demand sides.
- Install data logging equipment and coordinate the data gathering process with production.
- Create baseline metrics, including electricity consumed to produce CFM and the CFM per widget produced.
- Make obvious repairs.
- Make demand-side improvements.
- Re-install data logging equipment.
- Evaluate compressed air activity.
- Replace air compressors on an as-needed basis, only if further system improvement is required.
Compressed Air Management: How To Breathe New Life Into Aging Systems
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