Most manufacturing facilities are unaware that their compressed air systems operate with significant inefficiencies. Research shows that a substantial portion of electricity used in these systems doesn’t contribute to productive output. These hidden inefficiencies steadily increase operational costs, affecting your factory’s bottom line. A comprehensive compressed air audit can identify these issues and provide practical solutions to improve system performance and reduce energy consumption. Additionally, a compressed air audit helps determine actual compressed air demand and air pressure requirements, which are critical for optimizing the compressor system.
A compressor’s lifetime energy costs make up 70-80% of total expenses. The original investment is just 8-10% of the total cost. On top of that, your typical industrial plant can slash operating costs by half through a compressed air energy audit. A complete audit process spots problems like pressure drops – each bar increase pushes energy use up by 7%. Understanding your current energy use and system dynamics is essential for identifying opportunities to save money and improve energy efficiency. Your audit checklist should have quality checks that boost system reliability and reduce maintenance needs. Implementing compressed air monitoring as part of your maintenance strategy will help identify issues before they become costly problems. This piece will get into why these audits are the foundations of reshaping your factory’s efficiency.
During the audit process, evaluating the existing compressed air system is crucial to assess its impact on your business and the environment.
Why Your Factory Might Be Wasting Energy
Compressed air systems cost manufacturing facilities more than any other utility. Energy makes up 70-80% of their total lifetime costs. Factory managers often don’t realise how much energy their systems waste each day. The Department of Industry, Science, Energy and Resources found that these systems waste up to 90% of their electricity. Businesses lose 30% of their energy on average. Some cases show waste levels reaching 60% through leaks, poor production or operational losses. Audits help identify inefficiencies and wasted energy usage in air compressors, allowing businesses to target areas where power consumption can be reduced and efficiency improved. Leaks waste 20-30% of all compressor output. Small leaks add up quickly. Even a simple leak can lead to significant air leaks and wasted power consumption. A single 1/8-inch leak at 100 psi wastes significant funds each year. Ten tiny 1/32-inch leaks at 100 psi pressure could cost your factory thousands of dollars annually. Here are other factors that lead to energy waste:- System over-pressurisation: Each 10 psi increase in compressor discharge pressure adds about 5% to electrical costs. Running at high pressures needlessly raises consumption by 1% per psi
- Inappropriate air use: Many operations use compressed air just because it’s there, not because it’s the best option
- Inadequate piping: Wrong pipe sizes create pressure drops that need higher pressure to compensate
- Poor maintenance: Dirty filtres, moisture problems, and neglected equipment make systems less efficient
- Monitoring compressed air usage and air usage: Regularly tracking usage helps match demand and operate the system more efficiently, reducing unnecessary energy usage and waste
How a Compressed Air Audit Works
A complete compressed air audit examines your entire compressed air system, including the air compressor, to find inefficiencies and ways to improve. The compressed audit assesses air demand, supply, and pressure loss throughout the system. Professional auditors use three different methods that vary in depth and complexity. The “Walk the Line” method offers the simplest approach. It involves visual inspection of major components inside and outside the compressor room, including filtres, pipework and condensation drains. This quick method needs no special hardware and spots obvious problems easily. Data logging proves the quickest way to get detailed analysis. The process places measurement devices throughout your compressed air system for 7-14 days minimum. These devices record data points every 0.5 seconds and average them over 20-second intervals. This extended monitoring captures peak operations and downtime that give a full picture of system performance. Air Scan, the most sophisticated method, can evaluate your entire system or target specific components. The components include air measurement, leak detection, air quality, maintenance reviews, and monitoring programmes. The audit can also recommend a more efficient machine or a tailored solution to improve your system’s efficiency, addressing issues such as pressure loss, air demand, and supply optimization. A proper data logging audit measures these critical parameters:- Flow rate and consumption patterns
- System pressure at multiple points
- Power usage (kilowatts)
- Moisture content (dewpoint)
- Temperature
Improving Air Quality and Dryness
Maintaining high air quality and proper dryness is essential for any efficient compressed air system. When air quality is neglected, moisture and contaminants can accumulate in the system, leading to rust, corrosion, and even damage to sensitive equipment and pipes. These issues not only increase the risk of leaks but also drive up energy costs as the system works harder to compensate for inefficiencies. One of the most effective ways to enhance air quality is by installing a reliable air dryer. An air dryer removes excess moisture from the compressed air, preventing water from entering the system and causing corrosion or blockages. This simple addition can significantly extend the lifespan of your equipment and reduce the frequency of costly repairs. Regular maintenance of the air dryer and other filtration components is equally important. Over time, filters can become clogged and dryers may lose effectiveness, so routine checks ensure that your compressed air system continues to operate at peak efficiency. By prioritising air quality and dryness, businesses can reduce energy costs, minimise downtime, and maintain a more reliable and efficient compressed air system overall.Common Issues with Bad Piping
Bad piping is a frequent culprit behind inefficiencies in compressed air systems. When piping is poorly designed or installed, it can cause significant pressure losses, increase energy costs, and undermine the overall system efficiency. Common problems include pipes that are either too large or too small for the required airflow, excessive bends or fittings that create turbulence, and unnecessarily long pipe runs that add friction and resistance. These issues not only waste energy but can also lead to leaks and inconsistent air pressure, making it difficult for compressed air users to maintain optimal performance. For example, undersized pipes can choke airflow, forcing compressors to work harder and consume more electricity, while oversized pipes may result in unnecessary installation costs and slow system response. To avoid these pitfalls, it’s crucial to design and install piping systems with careful attention to airflow rates, pressure requirements, and the overall layout of your facility. Regular inspections and maintenance help identify and address bad piping before it leads to bigger problems. By tackling these common piping issues, businesses can improve system efficiency, reduce energy costs, and ensure their compressed air system delivers reliable performance for years to come.What You Gain from a Compressed Air Audit
Manufacturing facilities save much more money from compressed air audits than their original investment costs. Companies that invest in these efficiency improvements save over 15% on energy costs yearly, and the upgrades pay for themselves in less than two years. The results are even better for some industrial companies that cut their annual energy costs by up to 42% by following audit recommendations and implementing tailored solutions for their existing air system. A well-done compressed air audit gives several clear benefits:- Lower operating costs – Fixing leaks saves money fast. A single 1/4-inch leak costs thousands of dollars each year
- Increased reliability – Equipment breaks down less often when audits spot maintenance needs early
- Improved system efficiency – Finding and fixing pressure drops leads to better output with lower energy use
- Financial incentives – Many regions offer big rebates to companies that install energy-efficient equipment
- Audit solutions help businesses save money and operate more efficiently by identifying opportunities to optimize their existing air system
