How To Operate Your Industrial Air Compressor More Efficiently

It's no secret that in industry, compressed air is the most inefficient form of energy used on the jobsite. The cost of generating pneumatic power for various machinery tasks is prohibitive. Unfortunately, rotary screw air compressors are by design very inefficient. Electricity enters the factory from utility poles and does not produce power until it turns on the screw compressor, pressurizes the air ducts, proceeding through the workplace to its designated destination, and finally creates motion or action through pneumatic cylinders or devices. There is a lot of opportunities for waste in this complex and sophisticated system. Analysis and observation are the key to saving energy and producing the most useful pneumatic power at the lowest cost. Many deficiencies can be corrected once identified.

An air compressor is not just a machine. Air compressors produce energy and should be considered as a system, making them a compressed air system. Start by listing the uses of air and their design cfm and pressure. Record power consumption before making any changes to the system. This can be achieved using a kwh meter. Identifying and tracking leaks, most are easy to locate because they are located near the end-use point. Once the leaks are found, start repairing it. Of course, start repairing the line with the largest air leak. Installing a flow meters on the main line also helps to understand the savings in terms of cfm. Compressed air systems should also be operated at the lowest pressure possible after some major leaks have been repaired. Another tip is to install a normally closed air valve in the main line of each machine so that the entire machine can be taken off the compressed air circuit when not in use. Factory engineers also need to step back and analyze whether compressed air is even the best application for automation in the first place. Many point-of-use are operated inefficiently by the pneumatically operated design. Installing additional gauges and flow motors in the store can also lead to a better understanding of factory usage and misuse.

Compressed air systems are complex systems that requires constant monitoring. Saving energy costs is a priority for any factory or industrial facility, and an unmanaged air compressors can be the cause of a lot of waste. As you change and improve, don't forget to set a baseline and track your progress. This progress should be documented for decision makers within the organization.