Maximizing the Energy Efficiency of Your Compressed Air System

Air compressors are some of the most demanding energy users in a plant. In fact, over the life of an average compressor, the energy cost often exceeds the equipment cost several times over. Improving your air compressor’s energy efficiency can make a huge impact on your bottom line. Here are a few ways to reduce the cost of producing compressed air and maximize your energy savings:

Request a Compressed Air Energy Audit

Having a professional perform an air audit to measure your current flow rates, energy consumption and operating pressure can help identify significant cost savings. Often, evaluating things like how your compressors are controlled or whether you need extra storage can improve compressor efficiency. Air audits should be performed on a regular basis and any time changes have been made in your plant that may impact your compressed air system.

Find and Repair Air Leaks

Leaks in your system cause an unnecessary load on compressors, which inevitably requires more energy and maintenance. Without a proper air leak maintenance program in place, leaks in your air compressor could account for 20–30% of your total air demand and cost you thousands of dollars a year in wasted energy. Some leak surveys have actually enabled customers to completely shut down extra compressors.

Reduce Air Pressure

Less pressure = less energy. It’s that simple. According to the Compressed Air & Gas Institute, for every 2 psi reduction, you can save approximately 1% in energy consumption. Make sure your system hasn’t been set at a higher pressure than is necessary or requiring additional pressure as a result of leaks.

Maintain Your Equipment

Compressed air equipment is a big investment. Avoiding regular maintenance can lead to inefficient operation, costly repairs and even equipment failure. Following a consistent preventive maintenance schedule is a smart way to protect your investment and maximize savings. Changing filters and lubricants and having your equipment inspected regularly will keep it running efficiently and reduce your total cost of ownership.

Put Wasted Heat to Work

Compressing air naturally generates heat. Generally, this heat is wasted, but the majority of it can actually be recovered and used for operations like heating a warehouse or providing hot water for cleaning.

Use Your Energy Wisely

Too often, compressed air is used for tasks that could be completed more economically, such as using it as a blower to clean up or as a fan for cooling. Make sure your staff is educated on proper and improper uses of compressed air.

At Lewis Systems, we want to make sure you’re getting the most efficient performance from your system. Our factory trained service team can perform everything from ultrasonic leak detection to an in-depth Energy Audit and Air Study. We also offer maintenance and service plans to ensure your equipment is operating at peak efficiency. To discuss your energy needs, contact us at 800.222.4553.