Energy is the most expensive component of a compressed air system, and while it may seem insignificant, over the lifespan of your system, the energy typically costs several times that of the purchase price of your compressor.
Hence, one of the first measures you can take to reduce compressed air energy costs is to measure and monitor your energy consumption regularly to optimize usage.
90% of the cost incurred by the customer is energy
Small adjustments can help reduce your operating costs and improve output:
1. Fix leaks
It is estimated that up to 30% of the compressed air usage can be attributed to leaks from the system. If you can hear a leak, you should get it fixed!
However, approximately 80% of the leaks are inaudible, that is where the need for an air audit arises. Besides conducting an air audit, it is also recommended to invest in good piping material. Aluminium is the best option; it is anti-corrosive and durable.
Once you have fixed the leaks in the system, make sure that you allocate a team to conduct regular and timely checks. Be proactive and look inside the piping system. A clean, dry pipe indicates good quality air and no corrosion issues.
2. Choosing the right compressor
Bigger is not better for compressed air. Evaluate the needs of your business and the use of compressed air in that application. Inappropriate uses of compressed air will only result in wastage and further energy consumption.
- Selection of your air compressor as per the demand of your business
- Do not over size your compressor for future projects, you will end up wasting more power than your capital investment
3. Reduce Pressure
Evaluate your system requirements and use only the necessary amount of pressure. Avoid turning up the pressure to compensate for leaks or drops due to piping problems or clogged filters. Having less pressure in the system also reduces flow from unnoticed air leaks or leaks that cannot be immediately repaired.
The compressor pressure should be set as per that of the equipment pressure requirement. With increase of pressure by 1 bar your compressor consumes 7-8% more energy.
4. Proper maintenance
All industrial machinery run more efficiently when properly maintained. Proper maintenance cuts energy costs by one percent and helps prevent breakdowns that may result in loss of production. Most issues that may arise from time to time are fixable, if caught quickly.
ELGi helps you identify the energy saving opportunities for your compressed air and your organisation. Schedule an AIR AUDIT for your business with ELGi and make energy a priority to ensure big gains for your business.
Call us on: TOLL-FREE NUMBER: 1800 425 3544
or at CUSTOMER CARE NUMBER: +91 9790021100