Compressed air is one of the most expensive utilities in an industrial facility — yet, it’s also one of the most overlooked when it comes to energy efficiency. A well-optimized air system can significantly reduce operating costs, improve reliability, and extend the life of your equipment, saving you thousands!
Here are ten proven ways to make your air compressor system run more efficiently:
Air leaks are the silent energy thieves of any compressed air system. Even a small leak can waste thousands of dollars per year in electricity costs.
Tip: Conduct regular leak inspections using ultrasonic detectors or even soapy water, and repair issues promptly. Document recurring problem areas to prevent future losses. A leak detection system may help you identify costly leaks. Click here to learn more about Prosaris’ ultrasonic detection and management system.
Running your system at higher pressure than necessary can quickly drive-up energy costs. For every 2 psi increase in pressure, energy consumption rises by about 1%.
Tip: Set your compressor to the lowest pressure that still meets production needs and use regulators or storage tanks to balance pressure levels.
Clogged filters and dirty separators cause pressure drops that make your compressor work harder than it needs to, resulting in inefficiencies in your compressed air system.
Tip: Inspect and replace intake filters regularly, drain moisture from separators, and monitor differential pressure to keep air flow unrestricted.
Compressors perform best when drawing in cool, dry air. Hot, humid air reduces efficiency and increases the risk of moisture in the system, leading to a number of potential issues.
Tip: Position compressors in well-ventilated areas and ensure the intake air source is away from heat-producing equipment.
Up to 90% of the energy consumed by an air compressor is converted into heat — most of which can be recovered.
Tip: Install a heat recovery system to repurpose waste heat for space heating, process water, or other applications in your facility.
Routine maintenance not only prevents breakdowns but also keeps your system running efficiently. AT NCA Ltd., we pride ourselves on our ability to ensure that your compressed air system is regularly maintained to ensure peak performance and cost savings.
Tip: Stick to the manufacturer’s recommended service intervals. Check for unusual noise, vibration, or oil use, and keep detailed maintenance records.
Poor piping layouts can create significant pressure drops before air even reaches your tools or equipment.
Tip: Use properly sized piping with smooth, short runs and minimal bends. A loop-style distribution system helps maintain consistent pressure throughout your facility.
Leaving compressors running during non-production hours wastes energy.
Tip: Use automatic shut-off controls or timers to power down systems when not in use. Consider investing in variable speed drive (VSD) compressors to handle fluctuating air demand efficiently. NCA Ltd., offers a number of VSD compressors that can save you money by managing your varying air needs.
Oversized compressors are common in facilities with changing air needs — and they often waste energy.
Tip: Analyze your air demand patterns and consider multiple smaller units or VSD technology to better match output to usage. NCA Ltd., offers numerous high quality VSD models that may be beneficial to your fluctuating air requirements.
Moisture buildup affects air quality and can damage tools and downstream equipment.
Tip: Use automatic condensate drains and check traps regularly to ensure they’re functioning properly.
Improving the efficiency of your compressed air system isn’t just about saving energy — it’s about improving performance, reliability, and long-term profitability.
At NCA Ltd., we specialize in helping businesses get the most from their air systems through professional maintenance, energy audits, and quality Quincy Compressor products.
If you’d like to ensure your compressed air system is running at peak reliability, efficiency, and safety, get in touch with us today:
Phone: 519-659-2691
Email: info@ncaltd.ca