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How to Save Money With an Energy Efficient Air Compressor

April 28, 2016

Green light bulb showing idea for cost savings - Energy efficient air compressors

As you know, industrial air compressors can represent a significant cost in your annual budget. These costs may be amplified if the machinery is not well maintained. Normal use will naturally lead to wear and tear, but without regular upkeep, it can also lead to a broken compressor. This could mean lost production, unsafe contaminations or even physical damage and personal injury. In short, a faulty industrial air compressor system can be a major liability to your company. Fortunately, the reverse is also true; a well-maintained air compressor system can help increase energy efficiencies.

It’s true that the most expensive component in the total cost of compressed air is energy. Over the lifespan of a typical compressor, power typically costs several times more than the purchase price of the compressor. Small adjustments can save energy and money with a compressed air system. Correct management of an energy efficient air compressor just takes some basic outlining and planning. To protect your company’s compressed air systems investment, you may want to bear in mind the following tips to maximize the efficacy energy usage of the equipment. Here are five steps you can take to optimize your compressed air system and save energy costs.

5 Tips To Maintain and Save Money With an Energy Efficient Air Compressor

1. Monitor and Maintain the System

Today’s modern air compressor systems are relatively simple to operate, but to maintain the life of the system some basic maintenance is required. The first step to reducing compressed air energy costs is to measure and monitor the energy consumption, flow rates, and operating air pressure. Keep careful records of any and all data, including maintenance records to help supervise the health of the system over time.

2. Turn It Off

There are 168 hours in a week, but most systems only run at or near full capacity between 60-100 hours. Tracking usage, especially on systems with multiple units, can help to determine your company’s average capacity. Turn your redundant compressors off during the evenings and weekends demand is lower and you could reduce your energy bills up to 20 percent. Be careful not to try to overtax your system to save money however as it will minimize the life of the air compressor system.

3.Change Out Parts As Needed

Don’t try to save money on air filters or hoses by using them longer. Consider this: according to data from Energy Star, maintenance and repairs make up only 12 percent of an air compressor’s lifetime cost, which means investing in repairs will pay off a far greater return! Calculate the expected lifespan of each filter and replace them routinely to ensure optimum utilization. Air lines and end-use devices also have air filters, make sure to change these often too. Hoses can become weak and leak over time, so it is wise to check the hoses whenever you are replacing filters. Be vigilant for leaks in the system and fix any you find immediately. Because it takes energy to generate compressed air, any leaks left unfixed represent money leaking out of your company’s bottom line.

4. Retire and replace older compressors

It is sometimes difficult to find money in the budget for capital replacements. Often companies hold onto old units rather than incurring the costs to replace them. In reality, old air compressors rarely save money in the long run. Not only are newer air compressors more efficient, but products at the end of their life cycle tend to occur more in maintenance costs and foster leaks and issues that will add to the overall costs in the long run.

5. Recover Heat

Compressing air generates heat, so why not reuse it? As much as 90 percent of the heat produced can be recovered for use in your operation. For example, you can provide hot water or warm air with that heat.

As with most industrial machinery, a compressor runs more efficiently when properly maintained. Follow those five steps to save money and power with an energy efficient air compressor. Protect your reputation and profits with proper maintenance and quality systems. At Bistate Compressor, we use Quincy Compressor systems because of their performance and reliability. We’re here to help with advice on getting secure, energy efficient, proper air compressor systems.

Bi-State Compressor, Inc.
1571 Fenpark Drive
Fenton, Missouri 63026

Phone: (636) 349-8333
Fax: (636) 349-1411

Should the need ever arise, we offer 24 hour emergency service.

Rental units are also in stock, available for immediate hook-up.