Typically, energy costs contribute to more than 75% of the total life cycle costs of a compressor. Appropriate selection of compressors will result in optimal energy utilization, thereby reducing energy costs significantly for the user.

It is a proven fact that about 70% of an air compressor’s lifetime cost comes from power consumption, which then increases your overall power consumption However, due to the effectiveness and capacity of production support extended by compressed air systems, that it is now an indispensable part of the factory setup, especially in the case of sensitive industries including healthcare, pharma, food & beverage, etc.

Many opportunities exist to reduce the energy used by compressed air systems, beginning with air assessment and air audit. Here are 10 expert tips to help you keep a tab on your electricity bill.

1. LOWER THE PRESSURE: We all know that working under pressure can be hard. Every additional bar of pressure can increase your power consumption by 7%. Set your air compressor at the lowest possible pressure for a specific application. Remember that increasing pressure does not compensate for a pressure drop in the system caused due to leaks, faulty piping, or choked filters. Install a pressure regulator for better control. It’s also important to calibrate your pressure gauges at quarterly intervals.
2. CHANGE FILTERS ON TIME: While replacing air filters, it is mandatory to maintain the quality of air, it is also an energy-saving opportunity. Delaying an air filter change may cost you a lot. Clogged filters can lead to pressure drops and also hamper efficiency. Ensure on-time service for a healthy compressed air system.
3. INVEST IN PRE-FILTERS: Not only do pre-filters (also known as coalescing filters) help purify the air by removing oil and water, but they also help remove the particulate matter to a certain extent. Installing pre-filters for suctioning the air, and for its cooling, can extend the life of your compressor and its consumables.
4. CLEAN UP: Besides keeping your air clean, ensure that you give your compressed air system a thorough dusting every few months. The presence of sludge, dust, or grime can have a big impact on the efficiency of the compressed air system. Pay special attention to compressor coolers and heat exchangers. Consider investing in a dedicated low-pressure air compressor, and airline for cleaning, to save power.
5. PICK THE RIGHT DRYER: Selection of the right sized air dryer for your compressed air system is crucial. Make sure the energy consumption of the dryer is in proportion to the demand. An oversized dryer can add to your electricity bill significantly.

The use of compressed air spans rudimentary mechanic shops powered by decades-old reciprocating compressors to large scale textile units powered by high volume centrifugal compressors.  While the basic technology has remained fairly simple — powered pistons, screws, or impellers compress a volume of atmospheric air to a required pressure  — the design and use of compressed air systems have evolved to suit the industry needs.

Compressed air and power consumption

For manufacturers, achieving optimal efficiency is always a challenge as compressed air is inherently inefficient. Fossil fuels are more efficient in getting work done for the same amount of energy.  However, compressed air is among the best ways to safely store and use energy.  Thus, compressed air has remained a prevalent energy source for industry.  Manufacturers have innovated to reduce lifecycle cost, improve reliability, and improve air quality.

The Table below shows the typical lifecycle of a compressor.  Nearly 75% of the cost incurred over a ten year period comes from the power consumption.